USER'S GUIDE - Neopost

DS-90 DS-35
USER’S GUIDE

Table of Contents
1 Read this First ...............................................................................................1
Warning............................................................................................................1
About this manual.............................................................................................1
Safety...............................................................................................................2
Country Specific Conditions.............................................................................4
End of Life........................................................................................................5
2 Meet your Document System ......................................................................6
Overview..........................................................................................................6
Operating Controls...........................................................................................9
Control Panel..................................................................................................10
Installing the Document Feed Trays...............................................................11
Power Up........................................................................................................12
Home Menu....................................................................................................13
Job Info...........................................................................................................14
Side Guides....................................................................................................16
Document Orientation....................................................................................17
Filling the Document Feeder Tray..................................................................18
Loading Envelopes.........................................................................................19
Filling the Sealing Liquid Reservoir................................................................20
Shut Down the System...................................................................................21
3 Options ........................................................................................................22
MaxiFeeder....................................................................................................22
Installing the MaxiFeeder...............................................................................22
Adjusting the MaxiFeeder Side Guides..........................................................23
Adjusting the MaxiFeeder Document Separation...........................................24
Feeding documents (MaxiFeeder).................................................................25
High Capacity Document Feeder (HCDF)......................................................25
Installing the HCDF........................................................................................26

Adjusting the HCDF Side Guides...................................................................26
Document Separation for the HCDF..............................................................27
Feeding documents (HCDF)..........................................................................27
VersaFeeder (VF-3)........................................................................................28
Installing the VersaFeeder..............................................................................29
Operating controls (VersaFeeder)..................................................................30
Adjusting the Side Guides (VersaFeeder)......................................................30
Adjusting the Document Separation (VersaFeeder).......................................31
Hopper Capacity (VersaFeeder).....................................................................32
Support for Curved Reply Envelopes (option for VersaFeeder).....................33
Power Stacker Support..................................................................................34
High Capacity Envelope Hopper (EF-4).........................................................35
High Capacity Conveyor Belt (CS-2)..............................................................37
Installing the High Capacity Conveyor Belt....................................................37
Operating the High Capacity Conveyor Belt...................................................38
Catch Tray......................................................................................................38
Catch Tray on Left Hand Side........................................................................38
insert'n Frank / insert'n Mail ...........................................................................39
Mail Piece Production Control (MPPC)..........................................................39
4 Processing Mail Sets ..................................................................................41
Introduction.....................................................................................................41
Processing a Basic Mail Set...........................................................................42
Processing a mail set with BRE or inserts......................................................43
Document Separation.....................................................................................44
Adjustment of the Document Stoppers...........................................................45
Processing Daily Mail.....................................................................................46
Test Run.........................................................................................................47
Adjusting the Address Position.......................................................................47
Adjusting the Envelope Insert Fingers............................................................48
Verifying the Insert Position............................................................................49
5 Working with Jobs ......................................................................................50
What is a job...................................................................................................50

Creating a new job.........................................................................................50
Performing a test run......................................................................................52
Adjusting the Envelope Position.....................................................................54
Using a job.....................................................................................................55
Editing a job....................................................................................................55
Copying a job.................................................................................................56
Deleting a job.................................................................................................58
Job settings....................................................................................................59
Envelope settings...........................................................................................60
Document settings..........................................................................................61
Reading settings (option)...............................................................................63
Double feed control settings...........................................................................66
Job name........................................................................................................67
Exit select settings..........................................................................................67
Mailing/Franking settings (option)..................................................................72
Mail Piece Production Control settings (option).............................................73
6 Advanced Settings .....................................................................................74
What are Advanced Setting..........................................................................74
Opening the Advanced Settings.....................................................................75
Changing the Display Settings.......................................................................75
Viewing System info and Software versions..................................................77
What are licensed options............................................................................78
Activating an option........................................................................................79
Test Menu.......................................................................................................80
Running diagnostics.......................................................................................80
Job Settings (Supervisor)...............................................................................81
Flap Closer Offset..........................................................................................82
Envelope Clearing..........................................................................................83
System Output................................................................................................83
Changing Document Offset............................................................................84
Changing BRE Offset.....................................................................................85
7 Reading .......................................................................................................87

Introduction.....................................................................................................87
Reverse reading.............................................................................................88
Document Orientation....................................................................................89
BCR Code Description...................................................................................90
Reading a configuration sheet (BCR only).....................................................92
Running a BCR test........................................................................................93
OMR Code Description..................................................................................95
Running an OMR test.....................................................................................99
2-track OMR.................................................................................................101
8 Online Services .........................................................................................102
Online Services............................................................................................102
Start-up Online Services..............................................................................103
Connecting to the server..............................................................................104
Viewing the history.......................................................................................104
Viewing messages.......................................................................................105
Installing a new job or new software............................................................106
Configuration Menu......................................................................................107
Setting the telephone number......................................................................108
Setting the prefix..........................................................................................108
Selecting the country....................................................................................109
Entering date and time.................................................................................109
Setting the dial tone detection......................................................................110
Setting the modem volume...........................................................................110
9 Operator Maintenance .............................................................................111
Maintenance Schedule.................................................................................111
Clean and replace brushes..........................................................................112
Replace or clean moistening cloth...............................................................112
Resetting Photocells.....................................................................................113
10 Fault Finding .............................................................................................114
Error Messages............................................................................................114
Clearing Stoppages......................................................................................115
Envelope Hopper..........................................................................................116

Exit, Sealing and Inserting Area...................................................................117
Lower Envelope Track..................................................................................117
powerFold.....................................................................................................118
flexFeed........................................................................................................119
Collating Area...............................................................................................119
versaFeeder.................................................................................................120
Operator Troubleshooting.............................................................................121
Trouble Shooting Table.................................................................................121
11 Specifications ...........................................................................................125
Technical Specifications...............................................................................125
Hopper and feeder capacity.........................................................................126
Configuration Dimensions............................................................................126
Document and Insert Specifications.............................................................126
Envelope and Document Set Specifications................................................127
maxiFeeder Specifications...........................................................................128
versaFeeder Specifications..........................................................................129
High Capacity Envelope Hopper Specifications...........................................130
High Capacity Conveyor Belt Specifications................................................131
12 Terminology ..............................................................................................132
Terminology..................................................................................................132
13 EC Declaration of Conformity .................................................................138
EC Declaration of Conformity DS-90, M8800, FPi 6600, FD6604...............138
EC Declaration of Conformity MF-1.............................................................139
EC Declaration of Conformity VF-3..............................................................140
EC Declaration of Conformity EF-4..............................................................141
EC Declaration of Conformity CS-2..............................................................142

1
Warning
Read this First
1
About this manual
Ensure you have read and fully understood the safety requirements
in this section.
English
Languages
According to the EC (European Commission) declaration following the Low Voltage Directive
(2006/95/EC), this operator manual must be available in the national language(s) of the
country where the system is delivered. Therefore, if you do not have an operator manual
in your country’s language(s), contact your authorized distributor.
Software
The software used for the reading option is based in part on the work of the Independent
JPEG Group.
Audience
This manual is meant for operators of the document system.
Trademarks
maxiFeeder, insert'n Frank, powerFold, intelliDeck, flexFeed and versaFeeder
are trademarks of Neopost however the affix will not be used further in this manual.
1

Symbols
1
This manual uses the symbols listed below.
WARNING : Indicates a human safety hazard.
English
ATTENTION : A risk to the equipment or mail could result from an
action you may perform.
NOTE : A remark that explains different cases or specificities.
TIP : Advice to help save you time when processing your mail.
SUPERVISOR : Indicates that you have to use the supervisor
menu to perform the procedure.
Safety
Warnings
• Disconnect the power supply before performing any maintenance.
• Before connecting the system to the electrical supply, Ensure that the system is
suitable for the local mains voltage. Refer to the serial plate on your system for voltage
requirements.
2

Safety Precautions
• Only competent, trained personnel should operate this system. If non-trained
personnel do operate this system, the manufacturer will not accept responsibility
for any resulting accidents or injuries.
• Only skilled persons, who are aware of the risks involved, may open the protective
covers.
For safety reasons, the system will not function when the covers are open.
• Keep long hair, fingers, jewelry, etc. away from rotating and moving parts.
• The power connection must be easily accessible, preferably close to the system.
For safety reasons, it is essential that the system is connected to a socket outlet that
has a protective earth (ground) connection.
• Overcurrent protection in the equipment also relies on the branch circuit protection
(max. 20 A).
• The following part(s) is (are) considered the equipment disconnect device(s):
- Power supply cord plug or appliance coupler.
- 12-pole connector, located on the right-hand side.
1
English
CAUTION: DOUBLE POLE / NEUTRAL FUSING
(this means that after operating of the fuse, parts of the equipment
that remain energized, might represent a hazard during servicing.)
Precaution
The general process of automated document handling can sometimes create a build up of
static electricity. Therefore we recommend that the following measures are taken to reduce
the side effects of any electrostatic charge.
• Make sure that you operate the system within the recommended temperature and
humidity conditions.
• Make use of antistatic mats where appropriate.
• If necessary, make use of an ionizer to reduce static charge build up in the room
where the system is located.
Please contact your supplier for further information.
3

1
English
Country Specific Conditions
Denmark
In Denmark, certain types of Class 1 appliances may be provided with a plug that does not
provide an adequate earth (ground) connection when inserted into a Danish socket outlet.
Make sure the system has a good functioning connection that has protective earthing (the
plug and socket outlet must match).
Japan
• Establish an earth (ground) connection before connecting the mains plug to the power
supply.
• First disconnect the power supply before removing the earth (ground) connection.
4

End of Life
The objectives of the European Community's environment policy are, in particular, to
preserve, protect and improve the quality of the environment, protect human health and
utilize natural resources prudently and rationally. That policy is based on the precautionary
principle and principles that preventive action should be taken, that environmental damage
should as a priority be rectified at source.
Separating waste during collection is the precondition to ensure reuse and recycling of waste.
The proper disposal of electrical or electronic equipment is necessary to achieve the chosen
level of protection of human health and the environment in the European Community.
More particularly, certain materials and components of waste electrical and electronic
equipment need special treatment as improper handling or disposal on or into land, water
or air would represent a major threat to the environment and human health.
In order to facilitate collection and treatment separated from normal domestic waste,
electrical and electronical equipment is marked with the following logo:
1
English
By law, not only are you not allowed to dispose of the waste equipment via other waste
channels, but we encourage you to actively contribute to the success of such collection
and to the common good and better quality of life of present and future generations. For
more information on the correct disposal of this product, please contact your local service
organization.
5

2
Meet your Document
System
2
Overview
English
Introduction
The system is a folding and inserting system for processing mail easily. The system:
• feeds documents
• folds the documents
• inserts the documents into envelopes
• seals the envelopes
• stacks the envelopes
Automatic monitoring ensures the correct number of documents per envelope. The system
can be operated by means of a user friendly interface. The settings of the system (types
of documents, type of envelopes and the type of fold) is recorded in so called jobs. These
jobs can be programmed by an authorized user.
The system is equipped with a variety of special features, such as:
• document thickness detection
• programmable jobs
• automatic jobs
• flexFeed
• double feed control
• hopper swap
• multifeed
• daily mail
• intelliDeck
• powerFold.
6

2
English
The figure shows an overview of the system.
Document Feeders (flexFeed) (1)
The flexFeed is the feeding part of the system. There are two types of feeders: the automatic
and the special feeder. The automatic feeder does not require any adjustments for the
separation. From a feeder you can feed one or more documents (multi feed). The feeders
have a double feed control (DFC). DFC detects if more documents are fed instead of one.
You can link feeders. This means that two feeders can be linked as pairs. When the first
feeder is empty, the system switches to the other feeder. Meanwhile the empty feeder can
be refilled without stopping the system.
The upper automatic feeder is equipped with a 'daily mail' function. You can use this feeder
to process sets of documents that you cannot process automatically (stapled documents
and sets with varying thickness).
Collating Area (2)
All documents of a document set are collated and aligned in the collating area.
7

2
English
intelliDeck(3)
The intelliDeck automatically throws out incorrect sets of documents. In this way the system
does not need to stop. Correct sets will be transported to the powerFold unit.
powerFold (4)
The fold unit folds the documents. The following fold types are possible (see Terminology
on page 132):
• No fold
• V-fold
• C-fold
• Z-fold
• Double V-fold
Inserter (5)
After the documents are folded, the documents are transported to the inserter. The inserter
inserts the documents into a waiting envelope. The inserter seals the envelope or not,
depending on the settings. Automatic monitoring ensures the correct number of inserts per
envelope.
Present on Deck (6)
The documents inserted (or not) can leave the inserter from the upper unit (present on
deck). This can occur when:
• Clearing the machine;
• Making a test set;
• Depending on the reading code.
Stacker (7)
The documents inserted (or not) are transported to the stacker depending on the
programmed job. The stacker automatically stacks inserted documents.
Side exit (8)
The documents inserted are transported to the side exit depending on the programmed
job. The side exit can be used for sorting and stacking of documents into the catch tray as
well as transporting to the optional conveyor belt or franking/mailing machine.
Envelope Feeder (9)
Envelopes that are placed on a stack by the user, are fed one by one into the system by
the envelope feeder.
8

Operating Controls
2
English
A - catch tray (optional)
B - side exit / stacker unit
C - side guides stacker
D - power inlet, power switch
E - RS232 connector / USB / modem
F - unlocking lever for upper unit
G - display (operator panel)
H - vertical transport
I - hand grip vertical transport cover
J - document feed tray
K - collator arm
L - intelliDeck (divert)
M - powerFold
N - locking handle powerFold
O - handle for manual transport of the envelope
P - handle for manual transport of the mail
set
Q - unlocking handle for rollers envelope
track
R - sealing liquid reservoir
S - side cover (opened)
T - thumb wheel for side guide adjustment
U - side guides envelope feed tray
V - flap for envelope separation adjustment
W - envelope support
9

Control Panel
2
English
The control panel consists of the touch screen and the following buttons:
A: On/Off ( ): Switches the system on or off. If the system is not used for one hour,
the system switches to the power save mode. Press the On/Off button to switch back to
the user mode.
B: Stop ( ): The system completes the current mail set and stops, leaving the system
empty and ready for a new set.
C: Start ( ): The system starts to process mail sets.
The display is covered with a thin pressure-sensitive layer. To avoid
permanent damage of the display, do not use sharp objects to press
on the display.
10

Installing the Document Feed Trays
Place the document feed trays in position:
1. Hold the document feeder slightly inclined as shown in the figure.
2
English
2. Place the front end of the document feed tray underneath the two black rollers.
3. Move the document feed tray upwards (lifting the black rollers), until it is possible to
‘hook’ the feeder into place.
4. Move the document feed tray towards the machine and move the hooks over the
mounting points (on both sides).
5. Let the document feed tray rest on the machine.
11

Power Up
To start up the system:
2
You can severely damage the machine if it is connected to the
incorrect power supply. Before plugging in the machine, check if
the local voltage is the same as the voltage mentioned on the type
plate.
English
1. Connect the system to the mains power supply.
2. Use the power switch to switch the system on. The power switch is located on the
back of the system.
3. Press the on/off button next to the display. (Only necessary when the system is
in standby mode.)
The touch screen shows the home menu.
12

Home Menu
2
When you start up the system, the ‘home’ menu appears. With the arrows you can scroll
through the jobs. If you want more information on a job, select the job.
If you just want to start without job definition, press [New job] and select [Automatic] (see
Processing mail sets on page 41).
English
With the home button ( ) you get back to the home menu. The [Menu] button opens
the advanced settings menu (see Opening the Advanced Settings on page 75).
13

Job Info
2
If you want more information on a job, select the job in the ‘home’ menu.
The ‘current job’ menu shows the following information of the selected job:
English
• Job number and Job name
• Total: total number of envelopes that have been processed using this job
• To do: number of envelopes to do. Only indicated if a ‘stop at’ value is set.
• Stop at: number of processed envelopes at which the system stops. You can set this
number with the [Counters] button.
You can set it between 0 (switched off) and 9999. The system will continue until the
job counter reaches the stop counter value. The system stops and can be restarted.
The stop counter is switched off when it is set to zero.
If you want to reset the daily job counter and the stop counter, press the [Reset TOTAL
Counter] button in the ‘counters’ menu.
The counter settings are job related.
14

• A picture of the system with symbols for the selected features. The following
symbols can be used:
Shows the feeders selected to pick documents from (black
is selected). Every selected feeder shows how many sheets
will be fed from the feeder and the length of the sheets.
This sign indicates that the relevant feeders are linked. This
means that when one feeder is empty, the system automatically
starts picking documents from the other feeder.
This sign indicates that for the selected feeder OMR or BCR
is switched on (optional).
2
English
This sign indicates that the relevant feeder is set for daily
mail.
Gives information about the envelope size (ISO format or
height in mm). An envelope with a cross means that no envelopes
are used.
Shows the type of fold, in this case C-fold.
The sign indicates that for the relevant feeder the double
feed detection is switched on.
• [Edit]: use this button to edit the job (see Editing a job).
• [Info]: if you press the [Info] button, the screen shows how to position the envelope
and documents in the feeders. From this menu you can press a button to view the
reading settings and insert'n Frank / insert'n Mail settings.
15

Side Guides
2
To adjust the side guides it is best to remove the document feed tray from the feeder as
follows:
1. Push handle A downwards.
English
2. Lift the document feed tray upwards to unhook it and then pull it out from the feeder.
3. Loosen the knob B half a turn.
4. Grab the side guides in the middle and push them apart as far as possible.
5. Put a small stack of documents between the side guides.
6. Grab the side guides in the middle and push them towards the documents.The space
between the side guides and the documents should be such that the documents have
just enough play to move freely.
7. Re-tighten knob B.
8. Remove the stack of documents.
9. Replace the document feed tray (see Installing document feeders on page 11).
16

Document Orientation
2
English
In case the optional extended powerFold is installed, the following feeding rules apply to
documents with bottom address position:
17

Filling the Document Feeder Tray
Fill the document feeder tray as follows:
2
1. Open the left-hand side guide A by turning it downwards.
The feed rollers will automatically be lifted.
English
2. Place a stack of documents between the side guides.
3. Turn the left side guide upwards again.
4. Feed the documents (depending on the type of documents and the type of fold) (see
Document Orientation).
18

Loading Envelopes
Before you load the envelopes, make sure the envelope separation and side guides are
correctly set. Proceed as follows:
1. Rotate thumb wheel D to move the side guides C apart.
2
English
2. Put a small stack of envelopes between the side guides.
3. Move the side guides towards the envelopes. The space between the side guides and
the envelopes should be such that the envelopes have just enough play to move freely.
If the distance between the side guides is too large, the envelopes
will twist sidewards, when transported into the machine.
4. Pull down small lever B to set the separation.
5. Insert one envelope up to the stoppers. The position of the envelope is flap down and
trailing (bottom side of the envelope pointing to the system).
6. Return lever B.
7. Loosen the stack of envelopes and place the stack on top of the bottom envelope.
19

8. Shift envelope support A in or out. The top side of the envelope must touch the dotted
line on the support.
2
English
9. Turn envelope support A to distribute the weight of the envelopes evenly on both
sides.
Filling the Sealing Liquid Reservoir
1. Open the front cover B.
20

2. Fill the reservoir A to the "Max" lip with sealing liquid.
3. Close the front cover B.
Before starting the job, wait approximately 5 minutes for the brushes to moisten or use
moistened brushes. For instructions on the installation of brushes, see Clean and replace
brushes on page 111.
If the liquid reservoir is almost empty the touchscreen shows a message to warn you that
you should refill the reservoir.
Shut Down the System
1. Press the [On/Off] button to shut down the system.
When the system is busy, it completes and inserts the current set, stops and will be shut
down.
2
English
21

3
Options
MaxiFeeder
3
English
The maxiFeeder is a feeder that can be loaded with a high number of documents. This
feeder is intended to be used for Business Reply Envelopes (BRE), but also 'standard'
documents up to 356 mm (14") length can be processed with it.
Installing the MaxiFeeder
The maxiFeeder should be installed at the position of feeder no. 1 and/or 4. If you install
the maxiFeeder on position 4, you cannot use position 2 and 3 for document feeders.
To install the maxiFeeder as follows:
1. Lift the paper feed rollers with the front edge of the maxiFeeder.
2. Move the maxiFeeder forward until it hooks behind the frame axle.
3. Connect the connector A to the socket B.
The maxiFeeder is auto-detected by the system when the system is switched on. This
makes it easy to switch over from the standard document feeder tray to the maxiFeeder
and vice versa.
To make use of a maxiFeeder it is not necessary to (re-)program the jobs.
To allow easier hooking on of the maxiFeeder it is advised to put
the feeding plate in the rear position.
22

Adjusting the MaxiFeeder Side Guides
Adjust the side guides:
1. Take a stack of documents/BREs and place them in the feeder tray.
BREs with flap down and leading (top side pointing to system).
3
English
2. Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit
and can move without resistance.
Too much play causes skewing.
23

Adjusting the MaxiFeeder Document Separation
3
When the maxiFeeder is used at an automatic separation feeder, the separation is set
automatically.
The maxiFeeder can also be used on a feeder position with a manually adjusted separation.
To adjust, proceed as follows:
1. Remove the document feeder trays 2 and 3.
English
The lowest feeder is feeder 1.
2. Squeeze the two blue handles A and B and shift the feeding plate C as far as possible
to the front.
3. Push knob D forward until it clicks.
4. Place a document/BRE on the feeder tray and slide it in the system till the leading
edge is not visible anymore. Turn knob D counterclockwise if the separation is set to
narrow.
5. Push the document/BRE between the rollers.
6. Turn knob D clockwise to get more resistance and counterclockwise if the separation
is set to narrow.
The separation is adjusted correctly when a slight resistance is felt on the
document/BRE.
7. Pull knob D back when ready.
8. Replace the document feeder trays 2 and 3.
24

Feeding documents (MaxiFeeder)
To feed documents:
When filling the maxiFeeder, make sure that the document/BREs
are positioned parallel in relation to the feed plate to ensure correct
feeding.
The feeding plate assembly will be shifted up automatically (when the system starts
processing) until documents/BREs are underneath the rubber paper pullers.
1. Squeeze the two blue handles A and B.
3
English
2. Shift the feeding plate C to the rear position.
3. Loosen the stack of documents and place them in the feeder.
BREs with flap down and leading (top side pointing to system).
High Capacity Document Feeder (HCDF)
The High Capacity Document Feeder is an option that can be delivered from factory, or
added to a 2 or 4 station version by a service engineer. The High Capacity Document
Feeder has a capacity for up to 725 sheets. The normal document feeder tray has a capacity
of 325 sheets.
25

Installing the HCDF
To install the feeder tray of the HCDF:
3
English
1. Pull down lever A.
2. Hook in the feeder tray.
3. Release lever A.
Adjusting the HCDF Side Guides
To adjust the side guides B:
1. Loosen the knob D half a turn.
2. Put a small stack of documents between the side guides.
26

3. Rotate wheel E.
The space between the side guides and the documents should be such that the
documents have just enough play to move freely.
4. Re-tighten knob D.
Document Separation for the HCDF
The document separation is set automatically. There are no manual adjustments needed.
3
Feeding documents (HCDF)
To fill the document feeder tray:
English
1. Pull down lever A.
The feeder rollers C move up to filling level.
2. Place a stack of documents between the side guides (max. 725 sheets, 80 g/m²).
Feed the documents (depending on the type of documents and the type of fold) (see
Document Orientation on page 17).
3. Release lever A.
27

VersaFeeder (VF-3)
3
The versaFeeder is used to feed booklets, regardless of the thickness of the cover, to the
document flow from the feeder to the inserter. Because of the location of the
versaFeeder(downstream the feeder module) documents feeded by the versaFeeder will
not be folded.
English
When the versaFeeder is added to the configuration this is shown in the screens at the
display. The figure shows an example.
28

Installing the VersaFeeder
When installing the versaFeeder directly to the inserter, install the module in the following
manner:
Always switch off the system before connecting to, or disconnecting
from any attached units.
1. Disconnect the inserter connecting cable from the feeder module. Put the connecting
cable to the right hand side of the feeder module.
3
English
2. Place both hands under the left and right-hand side panel of the feeder module to
unlock it from the inserter.
3. Lift and uncouple the feeder module from the inserter. Move it backwards to create
enough space for the versaFeeder.
4. Place the versaFeeder between the inserter and feeder module. Place both hands
under the left and right-hand side panel.
5. Lift it above the inserter fixing plates and lower it until it locks into place. Both sides
are now locked.
6. Place both hands under the left and right-hand side panel of the feeder module.
7. Lift the feeder module above the versaFeeder fixing plates and lower it until it locks
into place. Both sides are now locked.
8. Connect the 12-pole connector of the inserter to the 12-pole socket located on the
right-hand side of the versaFeeder.
9. Connect the 12-pole connector of the versaFeeder to the 12-pole socket of the feeder
module.
The power inlet is located on the right-hand side of the feeder and contains the main
fuse.
29

Operating controls (VersaFeeder)
3
English
A - Separation adjustment wheel
B - Side guides
C - Hopper side guide adjustment thumbwheel
D - Release handle separation unit
E - Release handle feed unit
F - Feed unit push down area
Adjusting the Side Guides (VersaFeeder)
The side guides can be adjusted manually as follows:
1. Place a stack of documents into the feeder.
2. Adjust the hopper side guides B by turning the thumbwheel C. Provide just enough
space for the documents to move freely. Too much play causes skewing.
30

Adjusting the Document Separation (VersaFeeder)
The document separation can be adjusted manually as follows:
Check before the adjustment that the release handle D for the
separation unit is in the closed (down) position.
1. Turn the separation adjustment wheel A counter clockwise until a document can be
moved backwards and forwards without resistance.
3
English
2. Turn the separation adjustment wheel clockwise until a slight resistance is felt on the
document when the document is moved backwards and forwards.
3. Turn the separation adjustment wheel clockwise to get more resistance or counter
clockwise to lower the resistance.
4. Check the separation before starting the system. After starting the system it may occur
that more than one document at a time is pulled in. If this happens, turn the separation
adjustment wheel more clockwise to obtain correct operation. For poor feeding turn
the separation adjustment wheel counter clockwise.
31

Hopper Capacity (VersaFeeder)
To avoid irregular feeding there are three levels for the maximum heights of the hopper
capacity. The symbols for these three levels are printed on the right hand side guide of the
hopper. The level indication is a guideline.
3
Maximum hopper capacity of booklets with a tough cover (maximum
height: 250 mm).
English
Maximum hopper capacity for booklets with a weak cover (maximum
height: 150 mm).
Maximum hopper capacity for single sheets: minimum sheet quality: 80
gr/m2 (maximum height: 50 mm).
32

Support for Curved Reply Envelopes (option for
VersaFeeder)
Depending on the quality of the paper, the conditions during storage, etc. envelopes can
be curved. This can cause smaller reply envelopes to skew while being processed by the
versaFeeder.
A special support is available to allow curved envelopes to be correctly processed. It can
be used for envelopes with a height up to 110 mm (4.33").
3
English
To attach the support onto the hopper platform and adjust the support:
1. Hold the support as indicated by the figure.
2. Place both notches C at both sides into the sleeves.
3. Lower the other end of the support. It will lock fully into place.
4. Loosen knob B slightly by turning it counterclockwise.
5. Move support in or outwards until the ruler indicates the height of the envelope (the
side of the plate A is indicator).
6. Turn knob B clockwise to tighten the support.
33

Power Stacker Support
3
Depending on the inserted type and amount of documents, the filled envelopes may get
stack fanshaped at the stacker.
To prevent this, an optional power stacker support can be used in order to stack the
envelopes correctly.
English
34

High Capacity Envelope Hopper (EF-4)
For feeding large amounts of envelopes a high capacity envelope hopper can be installed.
To start up the high capacity envelope hopper:
1. Switch on the hopper.
3
English
To ensure correct feeding envelope support A has to be adjusted parallel. Proceed
as follows:
2. Move the high capacity envelope hopper backwards, away from the inserter.
3. Hold an envelope against the hopper plate B as indicated.
4. Place the envelope support A such that the envelope is aligned with recess C.
5. Apply the same alignment at the position of recess D.
6. Adjust the inserter side guides and the separation as described in Loading Envelopes
on page 19.
7. Put an envelope in the envelope height measurement area.
35

8. Rotate thumbwheel E to adjust the envelope height setting. The envelope should fit
exactly in the space indicated by the arrows.
3
English
9. Rotate thumbwheel F to adjust the side guides so, that the envelopes:- Fit exactly
between the side guides- Can move freely
10. Fill the envelope hopper with envelopes, positioned upside down. The flaps should
face the inserter.
11. Tip over the envelopes.
12. Load the envelope feeder of the inserter with about 50 envelopes.
13. Press the [Start] button.
36
The envelopes on the envelope hopper will be transported towards the feeder of the
inserter. Envelopes will be transported and dropped in the inserter feeder until the
envelopes reach a certain level. At that moment a sensor will detect the envelopes
and the high capacity envelope hopper will stop transporting.
When the sensor does not detect envelopes anymore the hopper will start again and
the process will be repeated.

High Capacity Conveyor Belt (CS-2)
The high capacity conveyor belt is designed for envelope transport from the inserter or
franking device. The conveyor belt has two operation modes:
• The belt moves continuously.
• The belt moves in intervals. The belt moves about 45 mm (1.7 inch) each time a
sensor detects the passage of an envelope.
The guide plate and side guides prevent the envelopes from falling off the belt.
Installing the High Capacity Conveyor Belt
3
English
To install the high capacity conveyor belt:
1. Move the conveyor belt to the correct position.
2. Connect the adaptor C to the connecting lead.
3. Connect the mains lead cable to the adapter.
4. Connect the mains lead cable to the socket outlet.
37

Operating the High Capacity Conveyor Belt
3
The conveyor belt switch has three positions:
• Mode D: the belt moves in intervals.
• Mode E: the belt is switched off.
• Mode F: the belt moves continuously.
English
Catch Tray
For stacking envelopes leaving from the side exit a catch tray can be mounted.
Catch Tray on Left Hand Side
Instead of a catch tray at the right hand (RH) side of the system it is also possible to install
a catch tray on the left hand (LH) side. To achieve this it is necessary to reverse the side
exit of the Stacker from RH to LH.
Contact your supplier for more information about this option.
This option can also be reversed.
38

insert'n Frank / insert'n Mail
If this system is connected to a mailing/franking system, insert'n Frank / insert'n Mail allows
you to:
• Switch automatic mailing/franking on or off
• Remotely select a mailing/franking job
• Set the printing/franking value (option)
• Automatically set the printing/franking value using the inserter data
For programming this option, see Mailing and Franking settings on page 72. Refer to the
appendix for an extensive description of the mailing (franking) option.
Mail Piece Production Control (MPPC)
The document system can be equipped with Mail Piece Production Control. This option
enables the system to verify the inserted documents or sets of documents with a database,
which is generated when printing the documents. The system will give a warning when a
mail piece is missing at the exit of the inserter. MPPC can be used together with a catch
tray or with a conveyor belt.
Refer to the appendix “Mail Piece Production Control” for an extensive description of this
option.
3
English
39

3
English
40

4
Processing Mail Sets
Introduction
With the system you can process mail sets in the following ways:
• Automatic job: The system automatically picks one sheet from each filled feeder
and processes them into mail sets.
The automatic feature is described in this chapter.
• Manual job: various settings, not available in an Automatic job, can be stored for
re-use in user-programmable jobs (Manual jobs). This includes the use of daily mail.
Working with manual jobs is described in What is a job on page 50.
Automatic job processes mail sets according to the following rules:
• The machine picks one sheet from each filled feeder;
• The picked documents will be folded (if necessary) and inserted into an envelope;
• Only the feeders that feed successfully will be selected;
• Only the Double Feed Control (DFC) of the upper feeder will be selected (this is done
automatically).
The following features are not supported with Automatic job processing.
• Linked feeders (the option where, if one feeder is empty, the system automatically
continues using another feeder);
• Multifeed (picking more than one sheet from a certain feeder);
• Daily mail (see Processing Daily Mail on page 46);
• Reading functionality (see Reading Introduction on page 87);
• No envelope mode (see Envelope settings on page 60);
• Envelopes with open flap (see Envelope settings on page 60);
• Exit select (see Exit select settings on page 67).
If you want to use any of these features, you have to use Manual jobs to process the mail
set (see What is a job on page 50).
4
English
41

Processing a Basic Mail Set
A basic mail set consists of documents from one or more document feeders. This set is
inserted into an envelope.
Before you start, make sure you have read the Introduction on processing mail sets.
4
1. From the home menu, press the [New job] button.
2. Choose [Automatic] to start an Automatic job.
3. Load the documents and envelopes into the feeders.
English
4. Press the [1x] test run button to create one mail set and follow the instructions on
screen.
After a successful test run, it is possible to use the [Save] button
to save the settings of the Automatic job to a new job.
5. Press the [start] button to start the mail set production.
The system stops producing mail sets when one of the feeders is empty or the [stop] button
is pressed.
42

Processing a mail set with BRE or inserts
A mail set with BRE consists of documents from one or more document feeders and an
insert/BRE from the BRE feeder. This set is inserted into an envelope.
Before you start, make sure you have read the Introduction on processing mail sets.
Load the BREs with the flap down (flap leading).
1. From the home menu, press the [New job] button.
2. Choose [Automatic] to start an Automatic job.
3. Load the documents, BREs or inserts and envelopes into the feeders.
4
English
4. Press the [1X] test run button to create one mail set and follow the instructions on
screen.
5. Press the [start] button to start the mail set production.
The system stops producing mail sets when one of the feeders is empty or the [stop] button
is pressed.
43

Document Separation
4
English
The term ‘Document separation’ refers to the adjustment required for separating the upper
document from the rest of the documents in the stack. This prevents pulling too much
documents from the stack at the same time.
The document separation for the automatic feeders is set automatically; there are no manual
adjustments needed.
Feeders 1 and 2 (the feeders in the two lowest positions) can be special feeders. The
document separation for special feeders must be adjusted manually. While special feeder
trays fit in all positions, adjusting the separation is only possible when they are fitted on
position 1 and 2.
Adjust the separation of special feeders as follows:
Adjusting the separation (using a special feeder) is especially
important when you want to process glossy materials.
1. Push the knob A forward until it clicks.
2. Place a document on the feed tray and slide it about 60 mm (2.4 inch) into the system
(turn the knob A counter clockwise if the separation is set too narrow).
3. Push the document between the separation rollers, which are behind the rubber paper
pullers.
4. Turn the knob A clockwise to get more resistance or counter clockwise to lower the
resistance.
The separation is adjusted correctly when a slight resistance is felt on the document.
5. Pull the knob A back again when ready.
44

Adjustment of the Document Stoppers
The document stoppers mark the position at which the documents coming from the feeder
turn towards the folding area. The position of the document stoppers is automatically
determined by the system during the job programming.
Initially the document stoppers are adjusted for position B. In this position a wide variety
of documents can be handled (max. 297 mm; 11.7 inch) and adjustment is not needed.
4
English
When a job is selected in which a different stopper position has been programmed, the
operator has to put the document stoppers in the correct position as indicated by the display.
To adjust the stopper position:
1. Lift and hold the collator arm D.
2. Squeeze the stopper and pull the front side tab up.
3. Place the flat back tab into the correct slotted hole.
4. Push the stopper into position.
Stop position A can handle documents up to 148 mm (5.8 inch), stop position B can handle
documents up to 297 mm (11.7 inch) and stop position C can handle documents up to 356
mm (14 inch).
45

Processing Daily Mail
The daily mail function is only available when reading is not
activated. When daily mail is set, the links to the daily mail feeder
will be deselected automatically.
4
English
When the daily mail function is selected DFC is not available.
To process documents or sets of documents, which can not be processed automatically
(e.g. stapled documents), the top feeder is equipped with a daily mail switch.
To use the Daily Mail function:
1.
Select a job where the daily mail function is selected. You can recognize the daily mail
by the
icon in the job information menus.
2. Turn down the left side guide A of the upper tray. Now you can see the Daily Mail
handle B.
3. Move the handle to the right to enable the Daily Mail function.
4. Turn side guide A upwards.
5. Press the [start] button to start the job.
6. Place the document or document set in the feeder (see Filling the Document Feeder
Tray on page 18).
The document or document set will be folded and inserted into the envelope as
described in the selected job.
7. Place the next document or document set in the feeder. The system will keep running
to process the inserted document or document set.
46

8. When finished with Daily Mail, press the [stop] button to stop the job.
9. Set the Daily Mail handle B to the ‘AUTO’ position to disable the Daily Mail and enable
the automatic document separation.
Test Run
Before starting an Automatic job, it is possible to perform a single test run.
This test run is intended to validate the settings of the Inserting System:
• Inspect and adjust the stop position of the envelope.
• Check the fold settings for one set.
• Check if the address is correctly positioned behind the envelope window.
Adjusting the Address Position
If the address on your mail is not correctly positioned behind the envelope window, change
the address position as follows:
4
English
Adjusting the address position is only possible after running a test
run (by using the [1x] button).
1. Choose a job and press the [1x] button.
2. Press No if asked if the mail set is correct.
3. Press Yes if asked if the documents are inserted correctly.
4. Press No if asked if the address is readable.
5. Follow the steps in the wizard.
47

Adjusting the Envelope Insert Fingers
To make a good insert of the document set into the envelope, the insert fingers A should
be about 5 mm (0.2 inch) inside the envelope.
The outer fingers D should be about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the
envelope.
4
English
To verify that the position of the fingers is correct:
1. Choose a job and press the [1x] button.
2. Follow the steps in the wizard.
To adjust the envelope insert fingers:
1. Loosen the knurled knob C on top of each finger.
2. Adjust each finger so that the tip enters about 5 mm (0.2 inch) into the envelope.
3. Re-tighten the knurled knob.The fingers can be moved sideways to the desired position.
4. Place the outer fingers about 5 to 10 mm (0.2 to 0.4 inch) from the edges of the
envelope.
Check the position of the insert fingers when changing to a different
type of envelope.
48

Verifying the Insert Position
To make a good insert of the document set into the envelope, the envelope should be
positioned correctly. The document set is inserted correctly if the flap folding line of the
envelope is positioned under the blue indicator B.
4
English
To verify the insert position:
This adjustment must only be checked in case of problems or when
changing the envelope type.
1. Choose a job and press the [1x] button.
2. Lift the unlocking lever of the upper unit and pull up the upper unit.
3. Press No until the question about envelope position appears.
4. Press No again and follow the instructions on screen.
49

5
Working with Jobs
What is a job
5
English
If you have to process a lot of mail sets of the same type (for example bills), you can save
the settings to a 'job'. The next time you just select the job and immediately start without
defining any settings.
The following settings are saved in a job:
• Envelope type/size;
• Sealing on/off;
• Which document feeders should be used, how many documents should be fed from
each feeder and document height for each feeder;
• Feeder linking on/off;
• If BREs or insert cards should be included;
• Address position;
• Fold settings;
• Double feed control settings;
• Reading settings (option);
• Exit select settings;
• Mailing and Franking settings (option);
• Mail Piece Production Control settings (option);
• Batch Counter, defining the number of mail sets that the job must process. The job
will automatically stop processing when this number is reached.
Creating a new job
To create a new job:
1. From the home menu, press the [New job] button.
50

2. Press [Manual] to create a new job.
For [Automatic], see Processing a basic mail set on page 42.
5
3. Enter the pin code 2546.
English
4. Press the [Job wizard] button to create a new job with the job creation wizard or press
the [Advanced] button (experienced users only) to define the settings of the new job.
If you use the job creation wizard, follow the steps on screen. If you use the advanced
way of job programming, continue as follows:
51

5. Press [OK] to confirm the selected free job number.
A new selected job number starts with default settings.
The job settings menu opens. The meaning of all buttons and settings is explained in
Job settings on page 59.
5
English
6. Press [Save] to save the job with the entered settings under the specified job number
and name.
To name a job, see Job name settings on page 67.
7. Press the [1x] button to verify that the insert position and address position are correct
(see Verifying the Insert Position on page 49 and Adjusting the address position on
page 47).
Performing a test run
Before starting a job, it is possible to perform a single test run with the settings of the current
job.
To perform a test run:
1. In the home menu, use the arrows to scroll through the Job selection list.
52

2. Select the job you want to use.
3. Click the [1x] button.
5
English
4. Press the button if you want to adjust the envelope position before running
the test run (see Adjusting the Envelope Position on page 54).
5. Press the button if you to perform a test-run to test the exit select settings (see
Exit select settings on page 67).
6. Press the [1x] button to perform the test run.
53

Adjusting the Envelope Position
Before performing a test run, it is possible to adjust the envelope position.
To adjust the envelope position:
1. Press the button to start adjusting the envelope position.
5
English
2. Use the arrows beneath the ruler to adjust the envelope position.
3. Press the to check the new alignment.
4. Press the [OK] button to accept the new alignment.
54

Using a job
If you want to use an existing job:
1. From the home menu, select the job you want to use.
5
2. If you want to perform a test run:
Press the [1x] button to do a test run.
3. If you want to change the counter for this job:
Press the [Counters] button to make changes to the amount of mail sets that the job
produces.
4. Press the [Start] button to start the job.
English
Editing a job
To edit an existing job:
1. From the home menu, select a job you want to edit.
2. Press the [Edit] button.
55

3. Enter the pin code 2546.
The job settings menu opens. See Job settings on page 59 for the meaning of all
buttons and settings.
5
English
4. Press [Save] to save the job with the entered settings under the specified job number
and name.
5. Press the [1x] button to verify that the insert position and address position are correct
(see Verifying the Insert Position on page 49 and Adjusting the address position on
page 47).
Copying a job
To copy existing job settings to a new job:
1. Press the [Supervisor] menu button from the main menu.
2. Enter the pin code 2546.
56

3. Press the [Job] menu button.
The job menu opens.
5
4. Press the [Copy job] button.
The copy job menu appears.
English
5. Press the arrows if you want to select another job number to copy from or to copy to.
You can only copy job settings to new jobs.
6. Press the button for details of the job to copy from.
7. Press [OK] to copy the job settings.
If all jobs are programmed the touch screen shows “No more free jobs”.
It is possible to copy an Automatic job into a job. Before an Automatic job can be
copied, it has to be defined successfully (see Processing a basic mail set on page
42).
57

Deleting a job
To delete an existing job:
1. Press the [Supervisor menu] button from the main menu.
2. Enter the pin code 2546.
5
English
3. Press the [Job menu] button.
The job menu opens.
58

4. Press the [Delete job] button.
The delete job menu appears.
When you press [OK], the job is deleted without a warning.
5
5. Select a job number and press [OK].
English
Job settings
From the job settings menu the following settings are available:
• Envelope settings (see Envelope settings on page 60);
• Document settings (see Document settings on page 61);
• Fold settings (see Fold settings);
• Reading settings (if installed, see Reading settings);
• Double feed control settings (see Double feed control settings on page 66);
• Job name settings (see Job name settings on page 67);
• Exit select settings (see Exit select settings on page 67);
• Mailing/Franking settings (if installed) (see Mailing and Franking settings on
page 72);
• Mail Piece Production Control (MPPC) settings (if installed) See the appendix
operator manual Mail Piece Production Control.
If you want to view the job details of the current job, press the
run a test, press the [1x] button.
button. If you want to
59

Envelope settings
In the ‘envelope settings’ menu you can define the envelope properties and switch the
sealing on and off.
5
English
In the top of the screen, three selection buttons are displayed, from which one can be
selected. The selected settings button will be highlighted.
•
Press the
button to select an envelope with closed flap. This means that the
envelopes are fed with closed flap. Use the first button to enter the applicable
dimensions. It is also possible to select ISO standard envelopes or dimensions in
inches (depends on the installation settings). The envelope height can be set between
90 mm (3.5 inch) and 162 mm (6.38 inch). Use the second button to enter the
weight of the envelopes in grams. Weight information is used for selecting exit settings
Exit select settings on page 67.
Use the
• Press the
button to define wether the envelopes have to be sealed or not.
button to select an envelope with open flap. This means that envelopes
are fed with open flap. Use the upper button to enter the applicable dimensions.
The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch).
It is also possible to select ISO standard envelopes or dimensions in inches (depends
on the installation settings). Use the second button to enter the flap height. The
flap height can be set between 32 mm and the envelope height minus 32 mm (1.26
inch).
• Press the button to define a job without inserting the documents in envelopes
(no envelope mode). This can be useful for jobs, where documents only have to be
sorted and/or folded. In this case, the exit will be set to the stacker.
60

Document settings
In the ‘document settings’ menu you define the document formats and the number of
documents that must be picked from the different feeders.
•
Press the
button to set the number of sheets for the different feeders.
5
• Press the button to select a feeder. The selected feeder is highlighted.
• You can feed more than one document for your document set from each feeder. This
is called Multi Feed.
Press the arrows to change the number of sheets that must be picked from the
highlighted feeder. When the number of documents is 0, the selected feeder will be
deselected.
English
When a feeder is set to daily mail the number of documents is
always 1 and can not be set in this menu.
The maximum number of sheets in a set is 25. When folding is used
the maximum set thickness is 8 sheets in letter fold and 10 sheets
(80 gr./m2) in single fold.
61

•
Press the button to enter the document height. The height or the ISO format of
the document will be displayed next to the relevant feeder.
5
English
• Press the button to select a feeder. The selected feeder is highlighted.
•
Press the button to show a numeric keypad to enter the exact dimension of the
document.
Dimensions can be entered in mm, inches or as standard ISO paper dimensions
(depending on installation settings). The system will not allow entering dimensions
out of technical ranges. The document size can be set between 90 mm (3.54 inch)
and 356 mm (14 inch).
• The default document size setting of a new job is 297 mm (11.7 inch).
•
Press the button to link two feeders. This function enables to fill two adjacent
feeders with the same documents. When the first feeder is empty, the system
automatically swaps to the other feeder.
• Press the
button to select two adjacent feeders. The selected feeders will be
highlighted. Press the button to link two highlighted feeders. The will be displayed
between the selected feeders.
When linking two feeders, the program will automatically apply the
number and format of the documents of the lowest feeder to the
other feeder.
62

When a feeder is selected for reading, the feeder below can not be
linked to this reading feeder. The reading feeder can be linked to
a feeder above when it is not selected for selective feeding.
•
Press the button to enter the setting of the daily mail function.
This function enables to process documents or sets of documents, which can not be
processed automatically (see Processing Daily Mail on page 46). The upper feeder
is automatically selected.
• Press the button to enable the daily mail function. The icon appears behind
the upper feeder. If you press the button again the daily mail function will be
disabled.
5
The daily mail function is only available when reading is not
activated. When daily mail is set, the links to the daily mail feeder
will be deselected automatically.
English
When the daily mail function is selected DFC is not available.
• Press the button to enter the document weights for all selected feeders. Weight
information is used for selecting exit settings Exit select settings on page 67.
Reading settings (option)
For a full function description of reading, see Reading Introduction on page 87. In the
‘reading settings’ menu it is possible to enable or disable the Optical Mark Recognition
(OMR) or Barcode Reading (BCR) function and to adjust the basic settings. The first ‘reading
settings’ menu covers the following settings:
63

Code type: default is the setting ‘none’: reading is disabled. Change the setting with
•
the button. The following codes are possible:
- 1-track OMR
- BCR for reading barcodes (1D as well as 2D barcodes)
- Flex 1-9 for reading customer specific codes (only if flex dongle is installed)
• Reverse reading: press the
reading).
button to set reverse reading on or off (see Reverse
5
• Read from feeder: press the
button to select a feeder to activate reading on.
By pressing the [Next] button the next reading settings menu appears.
English
In this menu you can define the location and the width of the OMR code. The position from
top should be between 15 mm (0.6 inch) and the document length minus 20 mm (0.8 inch).
If you press [Next], you can load an OMR sheet to verify the OMR settings. The system
processes the OMR sheet and shows the read marks. The information button shows the
interpretation of the marks.
If you selected BCR, you can update your barcode definition with a configuration sheet or
load a sample BCR sheet to learn the BCR location. The system processes the BCR sheet
and shows the read code. The information button shows the interpretation of the code.
By pressing the [Next] button the next reading settings menu appears.
64

• Stop on misread: define if the system should stop or not when a code is misread. In
case of “yes”, the system stops after a misread. The incorrect set is diverted. After
resetting the system, the final part of the set is also diverted and the system starts
processing again. The diverted set should be checked by the operator.
When “stop on misread” is set to “no”, the system does not stop after a misread.
The incorrect set is diverted. The final part of the set is also diverted and then the
system starts processing again. After 5 misreads in a row, the system stops and
an error code is generated.
• Stop on sheet overflow: define if the system should stop or not when a set exceeds
the maximum number of sheets, as defined at the "Max. sheets setting". In case of
“yes”, the system stops when the number is exceeded. The incorrect set is diverted.
After resetting the system, the final part of the set is also diverted and the system
starts processing again. The diverted set should be checked by the operator.
When “stop on sheet overflow” is set to “no”, the system does not stop when a set
exceeds the maximum number of sheets. The incorrect set is diverted. The final part
of the set is also diverted and then the system starts processing again.
• Max. sheets: use the arrow buttons to select the maximum amount of sheets in the
set of documents.
The maximum number of sheets in a set is 25. When the number
of sheets exceeds 8 or 10, depending on the fold, the document
can not be folded anymore. In this case, the maximum length of
sheets is 148 mm for a C5/6 envelope. Also make sure that the fold
is set to No fold. Ignoring this will certainly lead to stoppages.
When the maximum number of sheets exceeds the programmed
maximum number of sheets in a set, the system stops and error
VS:110 will be displayed. After removing the set and pressing the
[Reset] button, the system will start and repeat the process until
an insert or divert mark is encountered, error VS:135 (final set part)
will be displayed.
5
English
By pressing the [Next] button the next reading settings menu appears.
Select if an envelope leaves from the stacker if an exit code is read (‘on mark’) or if no exit
code is read (‘on space’). For the side exit the opposite applies.
65

Double feed control settings
In the ‘DFC settings’ menu you can set Double Feed Control (DFC) for the different feeders
on or off.
5
English
• Press the button to select a feeder.
•
Press the button to switch the DFC on or off.
When switched on, the icon is displayed. When a job is started, the first document
taken per feeder is used for a reference measurement.
When a document is exceeding that reference thickness an error will be displayed.
• Press the button to set Continue on double on or off. If Continue on double is on
(“yes”), the machine will not stop if two sheets are feeded instead of one. The
document-set containing the double sheets will be diverted.
When Daily mail is selected, the DFC will be switched off
automatically for the upper (Daily mail) feeder.
66

Job name
It is possible to store the job with a meaningful job name, to easily recognize the job. This
name is displayed at job selection. Enter a job name with the alpha-numeric keypad.
5
• Use the button to clear a character left of the cursor position (backspace).
• Use the [CE] button to clear all entered characters and start again.
Exit select settings
English
In the Exit select settings menu it is possible to change the sorting of filled envelopes that
leave the system.
You can choose between three or eight (if the optional reading is installed) selection criteria.
The screen dump shows the possible settings for an OMR job.
Possible exit settings are:
•
Select the
button to set a preferred exit.
Change the setting using the button. The following settings are possible:
- Stacker: if you select stacker you can choose to let the system continue on the
side exit if the stacker is full;
- Side exit.
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•
Select the
button if you want to create batches.
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English
Alternate batches of inserted envelopes are stacked or leave from the side exit
depending on the preset counter. The batch counter can be set from 1 to 500 in steps
of one inserted envelop per exit. Default the batch counter is set to 50.
•
Select the
thickness.
button if you want to select the exit depending on document-set
Use this menu to select the exit for document-sets that are too thin or too thick. At
the inserter the thickness is measured and compared to a reference thickness.
Depending on the selection in this menu the envelopes leave from the stacker or the
side exit. The first document-set determines the reference thickness.
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•
Select the
button if you want to select the exit depending on reading code.
The screen shows the selected exit if no exit code is read (space) or if an exit code
is read. The selection is set in the reading settings, see 3.9.5 ”Reading Settings
(Option)” on page 41. Use the button to set the exit mark toggle function to YES
or NO. When this function is set to NO and depending on how it is programmed in
the reading exit settings menu, envelopes leave from the stacker (or side exit) when
an exit code is printed. When no exit code is printed the exit will change and envelopes
leave from the side exit (or stacker). When this function is set to YES the exit will
change from the stacker to the side exit and vica versa each time an exit code is
printed.
•
Select the button if you want to select the exit depending on if the envelopes
are closed (sealed) or open (not sealed).
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English
This selection is only possible with reading: no mark (space) means sealed, a mark
means not sealed.
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•
Select the
filled envelope.
button if you want to select the exit depending on the weight of the
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English
Use the button to select which envelopes will leave from the stacker and which
from the side exit. The reference weight is calculated depending on the envelope
weight and the weight of the inserted document-set. The weight of the inserted
document-set depends on the amount of sheets (reading). To change the default
reference weight, press the
•
Select the
button.
button if you want to create batches depending on the reading codes.
The batch counter can be set from 1 to 500 in steps of one inserted envelop per exit.
Default the batch counter is set to 50. The preferred exit will change if the batch is
complete or an exit code changes. Use the button to set the exit mark toggle
function to YES or NO. When this function is set to NO and depending on how it is
programmed in the reading exit settings menu, envelopes leave from the stacker (or
side exit) when an exit code is printed. When no exit code is printed the exit will
change and envelopes leave from the side exit (or stacker). When this function is set
to YES the exit will change from the stacker to the side exit and vica versa each time
an exit code is printed.
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•
Select the button if you want to select the exit depending on the weight of the
filled envelope and reading codes.
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Use the button to select which envelopes will leave from the stacker and which
from the side exit. The reference weight is calculated depending on the envelope
weight and the weight of the inserted document-set. To change this default reference
weight, press the button. Press the button to see which exit the system chooses,
depending on the weight and the reading codes.
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Mailing/Franking settings (option)
If this machine is connected to a mailing/franking machine, this option allows you to select
the franking mode.
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English
Use the
button to choose between:
• Pass through: franking off
• Franking: the mailing (franking) system will print/frank the envelopes according to
the local mailing (franking) system settings. When you press the [Ok] button, you
can choose a franking job from the franking machine.
• Inserter: the mailing (franking) system will print/frank the envelopes according to the
size data communicated by the inserter. When you press the [Ok] button, you can
enter the weight of single documents and envelopes and the envelope width.
To link a mailing (franking) job to the inserter job, use the arrow buttons to select a
job. If no link is required, select ‘Current job’.
Refer to the appendix for an extensive description of the mailing (franking) option.
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Mail Piece Production Control settings (option)
For Mail Piece Production Control settings, see the appendix operator manual Mail Piece
Production Control.
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English
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6
Advanced Settings
What are Advanced Setting
Advanced Settings are all settings that can be found under the Display Settings Menu and
the Supervisor Menu.
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English
The Display Settings menu contains the following settings:
• Set screen brightness (see Changing the Display Settings on page 75);
• Set interface volume (see Changing the Display Settings on page 75);
• Change screen orientation (see Changing the Display Settings on page 75).
The Supervisor Menu contains the following settings:
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• System info (see Viewing System info and Software versions);
• Options (see Activating an option on page 79);
• Test (see Test menu on page 80);
• Online Services (see Start-up Online Services on page 103);
• Job menu (see What is a job);
• Read config sheet (see Reading a configuration sheet on page 92);
• Job settings (see Job Settings on page 81).
Opening the Advanced Settings
If you want to see or edit any of the Advanced Settings:
1. From the home menu, press the [Menu] button.
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English
2. Choose if you want to see the Display Settings or the Supervisor Menu. Press the
according button to enter that menu. Please note: to access the Supervisor Menu,
enter the PIN-code 2546. After entering the correct pin code the Supervisor Menu
appears.
Changing the Display Settings
From the Display Settings screen, you can change various settings.
To change the Display Settings:
1. Use the arrows next to the brightness symbol to increase or decrease the display
brightness.
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2. Use the arrows next to the volume symbol to increase or decrease the interface volume.
3. Press the button to toggle the orientation of the display screen. This function is
useful in case of applications when the operator is working on the backside of the
system.
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English
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Viewing System info and Software versions
From the Supervisor menu, you can view the System info and Software versions.
Proceed as follows:
1. From the Supervisor menu, press the [System info] button.
The System info menu opens.
Here, the following information is shown:
- Flex certificate - this option is used for OMR;
- Counter since last visit - the counter value since the last service visit;
- Last error - The last error generated by the system.
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English
2. Press the [Software versions] button to view information on the version of the installed
software.
The ‘software versions’ menu opens.
This screen shows the software versions that are present in the total system, see
example.
Pressing the [i] button shows the subversion revision numbers instead of the standard
software version numbers. Generally these are used for development reasons, but
sometimes it’s convenient to have them for trouble shooting reasons.
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What are licensed options
The Option menu shows the following information:
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English
• Chip ID
• System ID
• Installed options.
These software options are enabled using license codes. These license codes,
together with the identification number of the machine enable the relevant options.
The enabled and available software options are displayed in this screen. Contact
your dealer for information about these license codes.
The system supports the following licensed options:
- Advanced reading (see Reading Introduction on page 87);
- OMR 1 track (see OMR Code Description on page 95);
- OMR 2 track (see OMR Code Description on page 95);
- BCR 1D (see BCR Code Description on page 90);
- BCR 2D (see BCR Code Description on page 90);
- Flex reading (see Reading Introduction on page 87);
- insert'n Frank / insert'n Mail (INF) (see Mailing and Franking settings on page
72);
- MPPC (see the operator manual 'Mail Piece Production Control');
- OLS (see Online Services introduction on page 102).
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Activating an option
To add a licensed option:
1. In the Options screen, press the [Add] button.
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2. Use the keypad to enter the license key code that you received from the supplier to
activate the relevant option on this machine.
If needed, use the arrow keys to navigate through the entered characters.
3. Press the [OK] button to add the licensed option.
The system will now verify the license key.
4. Switch the system off and on.
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79

Test Menu
The Test menu can be used to check the system, reset all photocells and execute reading
tests.
The menu consists of the following functions:
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English
• Diagnostics - Use this function to check if all motors, clutches and sensors are
correctly connected. This test derives the status of the actuators and clutches by
briefly activating the actuators and then measuring the current (see Running
diagnostics on page 80);
• Reset photocells - Use this function to calibrate all photocells (see Resetting photocells
on page 113);
• OMR test - Use this function to test the OMR functionality (see Running an OMR test
on page 99);
• BCR test - Use this function to test the BCR functionality (see Running a BCR test
on page 93).
Running diagnostics
To run a diagnostics of the system:
1. In the Test menu, press the [Diagnostics] button. The Hardware test screen appears.
2. Remove all documents and envelopes and close all covers before starting the diagnose.
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3. In the Hardware test menu, press the [Start diagnose] button.
When the test is finished, the Status report is shown, showing a list of all problems
found during diagnostics.
4. If no problems were found, press the [OK] button.
If problems have been found that can not be solved, call your service organization.
Job Settings (Supervisor)
Job settings normally will be changed by a service engineer only.
Therefore first consult the supplier’s Helpdesk before changing any
settings. Changes to the job settings can result in malfunctioning
of jobs.
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English
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The "job settings" menu (supervisor) can be opened from the "supervisor menu". From this
menu system parameters can be set.
The "job settings" menu shows the following functions:
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English
• Flap Closer - Use this option to improve the envelope sealing process by changing
the flap closer offset for one or more defined jobs (see Changing the Flap Closer
Offset on page 82);
• Envelope clearing - Use this option to define when envelopes are cleared from the
system (see Changing the Envelope Clearing on page 83);
• System output - Use this option to change the output mode for one or more defined
jobs (see Changing the System Output on page 83);
• Document offset - Use this option to change the document offset for one or more
defined jobs (see Changing the Document Offset on page 84);
• BRE offset - Use this option to change the BRE offset for one or more defined jobs
(see Changing the BRE Offset on page 85).
Flap Closer Offset
To change the flap closer offset for a selected job:
1. Use the arrows next to "Select job" to select for which job (Job 1-25 or Auto) you want
to make the changes.
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2. Use the arrows next to "Flap Closer offset" to change the Flap closer offset for the
selected job.
The offset can be varied between -20 and 20. If for example the offset is set to +10
the sealing process will be activated 10 pulses later than initially.
3. Press the [Save] button to save the changes to the selected job.
Envelope Clearing
6
To define when envelopes are cleared:
1. Use the next to "Job selection" to set wether the envelopes should be cleared
(always, never or only after asking) when the operator selects a job.
English
2. Use the next to "Edit job" to set wether the envelopes should be cleared (always,
never or only after asking) after the operator has edited a job.
3. Press the [OK] button to accept the changes.
System Output
To change the output mode for a selected job:
1. Use the arrows next to "Select job" to select for which job (Job 1-25 or Auto) you want
to make the changes.
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English
2. Use the next to Output to change the Output mode for the selected job.
Mode 1 focuses on the versatility of paper parameters (paper thickness; document
length), i.e. correct operation under even extreme paper conditions.
Mode 2 is the default mode, and focuses on high speed and is achieved as follows:
- During multi feed (more than one page from one feeder) the movement on the
collator is minimal. In mode 1 the divert unit will be used for completing the
collating process.
- During the transportation of a set from the collator into the powerFold, the next
set is going into the collator already. This results in temporary overlapping sets
with two different transport directions. In mode 1 the set has left the collator
completely before the next set enters the collator.
- Anticipation call for the envelope is used. That means that a (folded) set is
leaving the powerFold already before the envelope is ready on the insert position.
In mode 1 the envelope is on the insert position already before the set leaves
the powerFold.
It is advised to use Mode 1 with a paper thickness of 65 g/m2 or less, a document
length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning
properly. In all other cases Mode 2 is advised.
3. Use the next to BRE with window to select if the reply envelope has a window or
not.
This option is only available for Output mode 2.
4. Press the [Save] button to save the changes to the selected job.
Changing Document Offset
To change the document offset for a selected job:
1. Use the arrows next to "Select job" to select for which job (Job 1-25 or Auto) you want
to make the changes.
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2. Use the arrows next to "Document offset" to change the Document offset for the
selected job.
The vertical transport of documents fed by the various feeders is arranged in such a
way that the documents are partially overlapping each other. This overlapping scheme
ensures that the documents are properly aligned in the collator area.
In the “document offset” menu you can set the extend to which the documents are not
overlapping each other, i.e. the document offset value. The default value is 50 mm
(2.0 inch). The document offset can be varied between 20 mm (0.8 inch) and 250 mm
(9.8 inch).
3. Press the [Save] button to save the changes to the selected job.
Changing BRE Offset
To change the BRE offset for a selected job:
1. Use the arrows next to "Select job" to select for which job (Job 1-25 or Auto) you want
to make the changes.
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English
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2.
Use the
button next to BRE with window to set the BRE offset to On of Off.
If a document is longer than the set address fold but shorter than the envelope height,
this document sometimes will be unnecessarily folded. Under certain conditions this
document can be prevented from being folded. This can be implemented with the
menu “BRE offset” (BRE means Business Reply Envelope).
For each of the jobs 1 through 25 and Automatic an offset can be switched on or off
using the button.
In the case of offset “on” the last document that was added to the set will be shifted
from the rest of the set (offsetting). This document will be held back during a certain
distance. This means that the trailing edge of this upper document leaves the collator
at last. This document will not be folded. During the insertion into the envelope the
documents of the set will be realigned.
The conditions are:
- The feeder that supplies this upper document (BRE) is set to one document per
set (no multi feeding).
- The document directly beneath this document must be at least 60 mm (2.4 inch)
longer than the BRE.
- The upper document must be longer than the set address fold.
- The folding mode is either V-fold or C-fold (no Z-fold).
- The upper document must be shorter than the envelope height.
The whole BRE offset is based on friction between documents within a set. Therefore
it is necessary to make use of these conditions to reduce the risk of bad transporting,
folding and inserting.
It is possible to use the BRE offset for a BRE and an enclosure
(card) in one set. The extra condition is that this enclosure is equal
to or smaller than the set address fold and should be placed direct
underneath the BRE in the set.
3. Press the [Save] button to save the changes to the selected job.
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7
Reading
Introduction
The reading option allows the system to read special codes that are printed on
the documents. The code contains information about the processing of the documents.
The system can read the following code types:
• 1-track OMR: Optical Mark Recognition
• 2-track OMR
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• BCR: BarCode Reading, 1D
English
• Barcode reading 2D
• Flex 1-9
Depending on the settings, the code tells the system if:
• The document set is complete
• Enclosures must be added to the set
• The system must stop
• The set is complete (no pages are missing)
• The envelopes are transported to the side exit or to the stacker
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The sheets with the printed code are placed in a feeder. Depending on the programmed
code, the other feeders can be used as selective feeders to add enclosures.
In case of a Z-fold, the address has to be printed on the last page of the set (see Document
orientation on page 89 for the code position). With the other fold types, the first sheet of a
set always contains the address. A full length code is printed on every sheet of a set. The
code must appear at the same location on every page regardless of the actual code length.
The code on the last sheet of the set contains the insert instruction (unless reverse reading
is used, see Reverse reading on page 88). The other sheets carry the accumulate
instruction. If a parity check is used with OMR, this is checked on each sheet. If the “page
n of m” code is used with BCR, the set will be inserted when n equals m.
General requirements for printing codes
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English
If you print documents for reading:
• Make sure the ribbon or toner quality is sufficient.
• Print the code in black.
• Codes on the same sheet must have equal intensity.
• Print the code at the same position on every sheet.
• Be aware of "background noise". The reading function can be disturbed by: color
changes on the form, background design and a logo or copy on the opposite side of
the sheet that will bleed through.
• For matrix printers near letter quality (NLQ) printed characters are preferred to obtain
maximum blackness (double strike).
For more information on how to print a reading code on your
document, contact your service organization.
Reverse reading
Reverse reading means that the insert mark (OMR) is on the first page of the set. The
system will detect the end of a set by detecting the first page of the next set. In case of
BCR use the Customer ID to complete a set. If the ID changes, the set is inserted.
When reverse reading is used, the reverse reading symbol is shown in the "Job info" screen.
In case the feeder runs empty, the last set is still on the collator because the beginning of
the next set could not be detected. In this case the feeder empty message contains
an [Ignore] function. By pressing the [Ignore] button the set on the collator will be inserted.
Because of the feeding and collating principle, reverse reading has the following limitations:
• The last mark of the code should be printed maximally 85 mm (3.3 inch) from the
top.
• Enclosures and selective enclosures cannot be handled.
When a versaFeeder module is added to the system configuration,
enclosures and selective enclosures can be handled with reverse
reading.
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Document Orientation
Switch on the reading function and set the position of the reading marks as described in
BCR Code Description and OMR Code Description.
Document orientation:
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English
89

BCR Code Description
Position of the code on the document.
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English
Minimum line thickness of a bar: 0.25 mm (0.01 inch)
The thickness ratio of thick bars versus thin bars: 2.2
The white area in the picture shows the limits where the code can be printed.
BCR license types
There are two BCR license types:
• Basic
• Advanced
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BCR basic license
For the BCR basic license the following functions are available:
• Page N of M: as long as N is below M, the document set is not complete. As soon
as N=M, the set is complete and will be inserted into an envelope.
• Insert/Accumulate: defines when a document set is complete and must be inserted
into an envelope.
• Customer ID: BCR uses the Customer ID code to complete a set. This is only possible
with reverse reading. If the ID changes, the set is inserted.
At least codes for accumulate and insert are required.
BCR advanced license
For the BCR advanced license the following functions are available:
• The basic functions (page N of M, insert/accumulate, Customer ID)
• Sheet sequence - Every sheet has a number, regardless of the document set it is
part of. If a sheet is missing, an error is generated.
• Group sequence - Every document in a set has the same group number. If one
document set is missing, an error is generated.
• Divert (Divert & Continue) - The set will be diverted and the system continues.
• Stop (Divert & Stop) - The set will be diverted and the system stops indicating error
(VS:113 - Reading stop - Stop mark read).
• Selective feed - If the system reads the command, an enclosure from the enclosure
feeder is added to the set. This function is printed on the last sheet of a set. It is also
possible to add an enclosure from the versaFeeder.
• Sealing control - Determines if envelopes are sealed or not.
• Present on Deck & Continue - The set leaves the system from the upper unit. The
system does not stop processing. The envelopes are not sealed.
• Present on Deck & Stop - The set leaves the system from the upper unit. The system
stops. The envelopes are not sealed.
• Exit selection - Determines if the envelope is transported to stacker or to the side
exit.
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English
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Reading a configuration sheet (BCR only)
If you want to set the code definition for BCR, you can use a BCR configuration sheet.
To read a configuration sheet:
1. In the Supervisor menu, press the [Read config sheet] button.The Barcode
configuration sheet menu appears.
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English
2. Load the barcode configuration sheet in the top feeder.
3. Press the [Run sheet] button.The BCR settings screen appears.
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4. In the BCR settings screen, confirm that all settings are read correctly.
Note that this screen consists of two parts. Use the arrows at the bottom of the screen
to navigate between the two parts of this screen.
5. Press the [Back] button to leave the BCR settings menu.
6. Press the [Save] button to save the BCR settings that were read from the configuration
sheet.
Saving these settings will change, depending on the chosen code
type, the barcode definition for jobs where 1D or 2D BCR (if
available) is used.
Running a BCR test
To run a BCR test:
7
Before running a BCR test, select a job that uses BCR reading.
1. In the Test menu, press the [BCR test] button. The BCR test menu appears.
English
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2. Press the [Test] button to start the BCR test. After the test is finished, the Result
screen appears.
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English
3. In the Results screen, evaluate the test results.
Use the button to see the BCR info, or use the button to cycle through all
BCR codes that were detected during the test. Select the one you want to use for
reading.
4. Press the [Back] button to return to the BCR test menu.
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OMR Code Description
Position of the code on the document:
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English
Minimum line thickness of a mark: 0.2 mm (0.008 inch)
Default the first mark from the top is set to: 100 mm (3.9 inch). This parameter is set in the
job settings.
The code must have a consistent number of marks on every page.
The white area in the picture shows the limits where the code can be printed.
OMR license types
There are two OMR license types:
• Basic
• Advanced
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OMR basic license
7
For the OMR basic license the following functions are available:
• Start mark: indicates the start of the code.
• Insert/Accumulate: defines when a document set is complete and must be inserted
into an envelope.
• Parity check: by adding a parity mark the reading code can be checked. The sum of
the marks must be even.
• Safety Mark: is used as an extra security (only 1-track OMR). With skewed paper
the reading head can miss part of the reading code. In these situations the safety
mark is not read, and the system will give an error. The safety mark also indicates
the end of the reading code. This mark must always be present on the document if
it is part of the code definition.
English
The minimum code is one mark in one line (insert). However for reliability it is advised to
use at least 2 marks. The first line is the start mark. A mark printed on the second line
means insert. No mark on the second line means accumulate.
In some cases, on request of the customer, the reading of the basic
commands can be reversed by the service organization. This means
that no mark is interpreted as an insert command and that for the
accumulate command a mark has to be printed.
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OMR advanced license
For the OMR advanced license the following functions are available:
• The basic functions (Start, Insert, Parity, Safety)
• Divert (Divert & Continue) - The set will be diverted and the system continues.
• Stop (Divert & Stop) - The set will be diverted and the system stops indicating error
(VS:113 - reading stop - Stop mark read).
• Selective Feed (feeder 1-6 and the versaFeeder) - If the system reads the command,
an enclosure from the enclosure feeder is added to the set. This function is printed
on the last sheet of a set.
• Exit control - Determines if the envelope is transported to stacker or to the side exit.
• Present on deck - The set leaves the system from the upper unit. The system does
not stop processing. The envelope is not sealed.
• Present on deck and stop - The set leaves the system from the upper unit. The system
stops. The envelope is not sealed.
• Sealing control - Determines if envelopes are sealed or not. If a mark is printed, the
envelope is not sealed.
• Sequence Check - Sheets in a stack can accidentally get out of sequence or can be
missing. This can be detected by the sequence check. Each sheet has a binary code
that is a part of the reading code. Depending on the application one, two or three
marks are used by sequence check.
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English
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OMR general remarks
General remarks:
• In case of OMR the marks must always be used in the sequence as shown in the
figure.
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English
• If a function is suppressed the following function will move upwards one line.
• The mark definition is a service setting.
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An Example of OMR Code
In the figure the legend for the following example is shown. In this example, a set of 8
sheets with one selective feed and three sequence check marks is shown.
• The first position is used for the start mark which must be printed on every sheet.
• The second mark position is used for the insert/accumulate command. A printed
mark means insert, no mark means accumulate. Therefore the mark is printed on
the last sheet of the set.
• Position 3 is reserved for selective feed from the enclosure feeder. Print a mark on
position 3 when a selective feed from the enclosure feeder is required. The marks
are printed on the last sheet of the set.
• Position 4, 5 and 6 are used for the sequence check marks. In this case a three mark
sequence check is used.
Running an OMR test
To run an OMR test:
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English
Before running an OMR test, select a job that uses OMR reading.
1. In the Test menu, press the [OMR test] button. The OMR test menu appears.
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2. Press the [Test] button to start the OMR test. After the test is finished, the Result
screen appears.
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3. In the Results screen, evaluate the test results.
Use the button to see the OMR info.
4. Press the [Back] button to return to the OMR test menu.
English
100

2-track OMR
2-track OMR uses two OMR-tracks to read OMR data. The main purpose of 2-track OMR
is reliability. The marks on the second track are inverted. This means that when a mark is
read at the first track, no mark (space) is expected at the second track.
The insert/accumulate and divert (stop and continue) are combined in two marks. The start
mark and safety mark are not available in 2-track OMR.
The table shows an overview of the OMR-marks for 2-track OMR. A stands for the first
track, B for the second track.
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English
101

8
Online Services
Online Services
The folding and inserting system can be equipped with Online Services. This option enables
the system to connect to a central server. During the connection data is downloaded to
and uploaded from the system. The system always initiates the connection, it is not possible
to make a connection from outside to the system.
Ask your supplier if this option is available.
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English
102

Start-up Online Services
To start-up Online Services:
1. From the supervisor menu choose [Online services].
The ‘Online Services’ menu shows the following functions:
- Connection: opens the ‘connection’ menu to create a connection to a central
server and to view the connection history (see Connecting to the server on page
104).
- Messages: opens the ‘messages’ menu to view received messages (see Viewing
messages on page 105).
- Configuration: opens the ‘configuration’ menus to change Online Services
settings (see Configuration Menu on page 107).
2. From the supervisor menu choose [Online services].
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English
The ‘Online Services’ menu shows the following functions:
- Connection: opens the ‘connection’ menu to create a connection to a central
server and to view the connection history (see Connecting to the server on page
104).
- Messages: opens the ‘messages’ menu to view received messages (see Viewing
messages on page 105).
- Configuration: opens the ‘configuration’ menus to change Online Services
settings (see Configuration Menu on page 107).
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Connecting to the server
The system makes a connection on fixed times. It is possible that you manually connect
the system to the server.
To connect to the server:
1. Press [Connection] in the Online Services menu. The touch screen shows the
connection menu.
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English
2. Press [Connect] to manually connect the system to the OLS server.You can view the
status of the connection on the screen. The text on the button changes to Disconnect.
3. Press [Disconnect] to terminate connection with the server.
The ‘connection’ menu shows the following functions:
- History: opens the ‘history’ menu to view the connection history (see Viewing
the history on page 104).
- New messages: this button appears when the system received new messages
and opens the ‘messages’ menu (see Viewing messages on page 105).
Viewing the history
The ‘history’ menu shows previous connections of the system to the server.
To view the history:
1. Press the arrows to select a previous connection.
104

2. Press the button to view details on selected previous connection.
Viewing messages
After pressing Messages in the ‘Online Services’ menu the touch screen will show messages
received from the server. A message has content like a new job or new software.
To view the messages:
1. Press the arrows to select a message.
In case a new job or new software can be installed the Continue button appears.
2. Press the button for more information over a selected message.
8
English
105

Installing a new job or new software
After pressing Messages in the ‘Online Services’ menu the touch screen will show messages
received from the server.
In case a new job or new software can be installed the Continue button appears.
8
To install a new job or new software:
1. Press [Continue].The new job available menu or new software menu appears.
English
2. Press the button for more information on the new job or new software.
3. Press [Install] to install the new job or new software
or
press [Reject] to reject it.After pressing [Install] a confirmation menu opens:
106

4. In case of a new job:
Press the arrows to select a free job number (see Creating a new job).
and
Press [OK] to confirm the selected job number or press Cancel to return to the ‘new
job available’ menu.
5. In case of new software:
Press [OK] to confirm the installation or [Cancel] to return to the new software menu.
After confirming the installation of the new job or new software the ‘message’ menu
appears.
Configuration Menu
After pressing Configuration in the ‘Online Services’ menu the ‘configuration’ menu opens.
Use this menu to modify the OLS settings.
8
English
The menu consists of two submenus containing the following functions:
• Telephone number of server: contact your supplier for the telephone number of the
OLS server.
• Prefix: use this function in case you need to dial a certain number or string to access
an outside line.
• Country: the country from where you are dialing.
• Date and time: current date and time.
• Dial tone detection on/off : This setting is required if no dial tone is heard during
establishing a connection. The default value is on. This setting is relevant to some
PABX telephone switch systems.
• Volume of modem: set the modem volume.
107

Setting the telephone number
To set the number:
1. Press the button next to the telephone number.
8
English
2. Enter the correct number using the numeric keypad.
3. Press [OK] to confirm the new number.
4. Press [OK] to confirm the modified settings and leave the Configuration Menu.
Setting the prefix
To set the prefix:
1. Press the button next to the prefix.
2. Enter the correct prefix using the numeric keypad.
3. Press [OK] to confirm the new prefix.
4. Press [OK] to confirm the modified settings and leave the Configuration Menu.
108

Selecting the country
To select a country from where you are dialing:
1. Use the up and down arrows to select the country from where you are dialing.
2. Press [OK] to confirm the modified settings and leave the Configuration Menu.
8
Entering date and time
To enter the current date and time:
1. Press the button next to the date/time.
English
2. Enter the correct date/time using the numeric keypad.
3. Press [OK] to confirm the new date/time.
4. Press [OK] to confirm the modified settings and leave the Configuration Menu.
109

Setting the dial tone detection
To toggle the dial tone detection:
1. Press the button next to dialtone detection to toggle the dial tone detection on/off.
8
2. Press [OK] to confirm the modified settings and leave the Configuration Menu.
English
Setting the modem volume
To set the modem volume:
1. Press the button next to the volume symbol to increase/decrease the modem
volume. Do not set the volume to zero as the sound of the modem is helpful during
remote assistance.
2. Press [OK] to confirm the modified settings and leave the Configuration Menu.
110

9
Operator Maintenance
Maintenance Schedule
Disconnect the mains power supply before performing any
maintenance.
The user must not attempt to service the appliance beyond that
described in this operator manual. All other servicing must be carried
out by qualified service personnel only.
Please contact your authorized distributor.
Maintenance
frequency
Daily
Weekly
When necessary
Maintenance
• Check the system functions.
• Keep the system in proper condition by removing
dust, paper remains, etc.
The machine is delivered with an extra set of brushes.
To always have one clean set available, it is recommended
to soak one set in water and use the other set.
• When dirty or saturated, clean the brushes of the
envelope sealing or replace them (see Clean and
replace brushes on page 112).
• When dirty or saturated, clean the moistening cloth
or replace if necessary (see Replace moistening
cloth on page 112).
• Clean feed and insert rollers as instructed by the
Service Engineer.
When the display warns about dusty sensors, clean the
applicable sensors. After cleaning, always calibrate the
photocells (see Resetting photocells on page 113).
9
English
111

Clean and replace brushes
When dirty or saturated, clean the brushes of the envelope sealing or replace them as
follows:
1. Moisten the new brushes in water.
2. Remove the brushes one by one by pulling them down from the brush holder.
3. Replace the brushes. Make sure that the studs on the brushes are fitted in the
corresponding holes in the brush holder.
9
Replace or clean moistening cloth
English
When dirty or saturated, clean the moistening cloth or replace if necessary. Proceed as
follows:
1. Remove the sealing liquid reservoir from the system.
2. Remove the cover with moistening cloth B.
3. Remove clips A to remove the moistening cloth.
4. Clean or replace the cloth.
112

Resetting Photocells
To calibrate all photocells:
1. In the Test menu, press the [Reset photocells] button. The Calibrate photocells menu
appears.
2. Remove all documents and envelopes and close all covers before starting the
calibration.
3. In the Calibrate photocells menu, press the [Cal.] button.
When the calibration is finished, the system returns to the Calibrate photocells menu.
9
English
113

10Fault Finding
Error Messages
When an error occurs the display shows a screen showing the following information:
• An indication of the area in which the error occurred
• An error description
• A suggested solution behind the pointing hand
10
English
Press the button to view more information about the occurred error and about the
possible actions to avoid the error from re-occurring.
After solving the problem, press [Reset] to reset the error (the error screen will disappear).
Special Errors
• Reading errors (when reading is enabled)
The document set is diverted. The operator must remove the document set and has
to complete the set manually!
• Technical errors
The display shows a message. The error cannot be solved by operating personnel
and assistance of the service support is needed.
Warning Screen
When a cover is opened, the display shows a warning screen with the message “Cover
open and a suggested solution “Close cover”.
114

Clearing Stoppages
Stoppages can occur in the following areas:
10
1. flexFeed area
2. Collating area
3. powerFold area
4. Lower envelope track
5. Moistening and inserting area
6. Sealing and exit area
7. Envelope hopper
English
115

For clearing of stoppages, five system sections can be opened:
10
English
A - loc, to reach the exit, sealing and inserting area
B - side cover, to reach the lower envelope track
C - powerFold cover, to reach the folding area
D - vertical transport cover, to reach the vertical transport and feeding area
E - collator arm, to reach the collating area
Envelope Hopper
When an envelope gets stuck in this area, remove the envelope as follows:
1. Pull down small lever B. Pins C will come down.
2. Push lever A to the right and hold it. Pins C will go up.
3. Remove the stuck envelope.
116

4. Release lever A.
5. Make sure the separation setting is still correct (see Loading Envelopes on page 19).
6. Return lever B.
7. Press the [Reset] button to reset the error and restart the job.
Exit, Sealing and Inserting Area
When a stoppage occurs in the exit, sealing and inserting area, remove the material as
follows:
1. Open cover A.
2. Remove all material.
3. Close the cover.
4. Press the [Reset] button to reset the error and restart the job.
10
Lower Envelope Track
When a stoppage occurs in the lower envelope track, remove the envelopes as follows:
English
If needed, envelopes can be transported manually to the insert table or lower envelope
track by means of handle C. To transport a mail set manually turn handle B.
1. Open the side cover.
117

2. Pull down the blue handle A.
3. Remove the envelope(s) from the lower envelope track.
4. Close the side cover.
5. Press the [Reset] button to reset the error and restart the job.
powerFold
When a stoppage occurs in the powerFold, remove the documents from the powerFold as
follows:
10
English
1. Push the lower end of the locking handle A to open the powerFold cover B.
2. Remove the documents from the powerFold.
If necessary use the delivered pin to turn the rollers. The pin is
delivered in the spare parts bag. Do not forget to remove the pin
when finished.
3. Close the powerFold cover.
4. Press the [Reset] button to reset the error and restart the job.
118

flexFeed
When a stoppage occurs in the flexFeed, remove the documents from the flexFeed as
follows:
1. Pull the vertical transport hand grip A upward to open the vertical transport cover B.
2. Remove the documents.
3. Close the vertical transport cover B.
4. Press the [Reset] button to reset the error and restart the job.
Collating Area
When a stoppage occurs in the collating area, remove the documents from the collating
area as follows:
10
English
1. Lift and hold the collator arm A.
2. Remove the documents.
119

3. Lower the collator arm.
4. Press the [Reset] button to reset the error and restart the job.
versaFeeder
When a document is blocked in the separation unit the document can be removed as
follows:
10
English
1. Open the release handle for the separation unit D.
2. Remove the documents. If necessary release the feed unit:
- Place your hand on the push down area F.
- Push down the release handle E.
3. Open the feeder.
The documents can be removed from the transportation area and from the rear side
of the separation rollers.
120

4. Close the feed unit:
- Place your hand on the push down area F.
- Push the feed unit down until it locks into place.
5. Press [Reset] at the inserter to reset the error and restart the job.
6. Place release handle D of the separation unit in the closed position.
Operator Troubleshooting
To resolve problems:
1. Write down the error.
2. Try to solve the problem by consulting the troubleshooting table.
3. Switch the inserter off and on again, to verify system operation.
4. When the error still occurs contact your service organization.
When contacting the service organization, you will also be asked
for the last error message and the software version of the installed
software. To determine the software version, see Viewing System
info and Software versions.
Trouble Shooting Table
10
Symptom
The system cannot
be started after
switching on.
System stops with
envelope at insert position
(flap not open).
Possible cause
System not connected
to mains.
Fuse is blown.
A cover is opened.
Envelopes stacked
reversed in the hopper.
Envelope flap sticks.
Wrong envelope type
used (not according
to specifications or
job settings).
Remedy
Connect the system
to the mains.
Replace fuse below
power switch.
Close the covers.
Check envelope feed
adjustments. Place
envelopes correctly in
hopper.
Store envelopes according
to specifications.
Change envelopes
according to specifications.
Reference
-
-
-
Loading Envelopes
on page 19
Envelope settings
on page 60
Envelope settings
on page 60
English
121

10
English
Envelopes are double
fed.
Envelope stops
skewed.
Envelopes are fed irregularly.
Flap is wrinkled and
sometimes not
opened.
Fingers are placed on
top of the envelope.
Envelope separation
not correctly set.
Envelopes not placed
properly in the hopper.
Side guides of the
envelope hopper are
set too wide.
Hopper almost empty.
Separation set too
narrow.
Side guides set too
narrow.
Envelope support not
positioned correctly.
Envelope not within
specifications.
Flap sticks.
Flap curled.
Separation set too
narrow.
Fingers adjusted too
deep into the envelope.
Envelope stops too
early.
Adjust envelope separation.
Check and replace if
needed.
Check side guides
and adjust if needed.
Refill hopper.
Adjust envelope separation.
Check side guides
and adjust if needed.
Reposition the envelope
support.
Check specifications
and change envelopes
if needed.
Store envelopes according
to specifications.
Envelopes stored or
manufactured improperly.
Adjust envelope separation.
Check fingers position,
adjust if needed.
Check envelope stop
position, adjust if
needed.
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Loading Envelopes
on page 19
Verifying the Insert
Position on page 49
Verifying the Insert
Position on page 49
Verifying the Insert
Position on page 49
Loading Envelopes
on page 19
Adjusting the envelope
insert fingers on
page 48
Verifying the Insert
Position on page 49
122

System stops while
inserting (stoppage at
the inserting point).
Flap not sufficiently
moistened.
Envelope not always
ejected from sealer.
Fingers not correctly
adjusted.
Inserted document
too long for used envelope.
Envelope throat incorrect.
Envelope glued inside.
Window not glued
properly.
Water level low.
Brushes dry.
Brushes dirty.
Moistening felt dry.
Moistening felt dirty.
Brushes worn out.
Moistening felt worn
out.
Inserted document
too big.
Document not inserted
deep enough.
Sealing area dirty.
Check fingers position,
adjust if needed.
Check fold settings.
Check envelope specifications.
Eliminate faulty envelopes.
Eliminate faulty envelopes.
Check water level,
refill if needed.
Check brushes, replace
if needed by the
extra soaked set.
Check brushes, clean
if needed.
Check the moistening
felt, refill water tray if
needed.
Check the moistening
felt, clean if needed.
Replace brushes.
Replace moistening
felt.
Check fold settings,
adjust if needed.
Check adjustment of
envelope stop position
and fingers.
Clean sealing area.
Adjusting the envelope
insert fingers on
page 48
Fold settings
Verifying the Insert
Position on page 49
-
-
Filling the Sealing Liquid
Reservoir on
page 20
Maintenance Schedule
on page 111
Maintenance Schedule
on page 111
Filling the Sealing Liquid
Reservoir on
page 20
Maintenance Schedule
on page 111
Maintenance Schedule
on page 111
Maintenance Schedule
on page 111
Fold settings
Verifying the Insert
Position on page 49
Maintenance Schedule
on page 111
10
English
123

10
No document fed.
Skewed documents
fed.
Double documents
fed.
Document set not
correctly inserted.
Address not readable
from window
Feeder empty.
Separation set too
wide / too tight.
Side guides set too
narrow.
Side guides set too
wide.
Separation set too
wide.
Insert position not
correct.
Insert fingers not correctly
positioned.
Address position not
correctly defined.
Refill feeder.
Filling the document
feeder tray on page
18
Adjust the separation. Adjusting Document
Separation on page
44
Adjust the side
guides.
Adjust side guides.
Adjusting the side
guides on page 16
Adjusting the side
guides on page 16
Adjust the separation. Adjusting Document
Separation on page
44
Check insert position.
Check insert finger
position.
Check address position.
Verifying the Insert
Position on page 49
Adjusting the envelope
insert fingers on
page 48
Adjusting the address
position on page 47
English
124

11Specifications
Technical Specifications
Model
Type
Theoretical max. speed
Power consumption
Voltage tolerance
Fuse
Approvals
Noise Level
Operating temperature
Humidity
DS-90, M8800, FPi 6600, FD6604
Folder and inserter system for medium office
use.
4300 inserts per hour, depending on application.
100V AC/50Hz/4.0 Amps.
115V AC/50/60Hz/4.0 Amps.
230V AC/50Hz/2 Amps.
100V: +6% / -10%
115V: +6% / -10%
230V: +10% / -10%
100/115 Vac: T 5.0 A, 125 V .
Time lag, 5.0 Amps. rated current, 125 V.
230 Vac: T 3.15 A H, 250 V.
Time lag, 3.15 Amps. rated current, high
breaking capacity, 250 V.
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15
CB Certificate conform IEC 60950-1
UL Listed I.T.E. (Information Technology
Equipment)
Conform UL-IEC 60950-1, file E153801
Conform NEN-EN-IEC 60950-1 and derivatives.

Hopper and feeder capacity
Envelope hopper
Document feeder tray
High Capacity Document Feeder tray
325 envelopes (80 g/m²)
325 sheets (80 g/m²)
725 sheets (80 g/m²)
Configuration Dimensions
2 stations
3/4 stations
5/6 stations
Height
820 mm (32.3 inch)
820 mm (32.3 inch)
920 mm (36.2 inch)
Width*
460 mm (18.1 inch)
460 mm (18.1 inch)
460 mm (18.1 inch)
Length
1500 mm (59.1 inch)
1500 mm (59.1 inch)
1500 mm (59.1 inch)
Weight
118.5 kg (261 lbs)
124.2 kg (274 lbs)
140.0 kg (308 lbs)
11
* Width with catch tray 750 mm/29.5 inch
Document and Insert Specifications
English
Paper quality
Paper size
Folding capacity
Minimum 60 g/m² (15 lb bond)
Maximum 250 g/m² (62.5 lb bond), when
folded max. 170 g/m² (42.5 lb bond)
Booklets up to approximately 2 mm (0.08
inch)thickness, depending on stiffness
Minimum width: 130 mm (5.1")
Maximum width: 242 mm (9.5"), when folded
230 mm (9.1")
Minimum length: 90 mm (3.5")
Maximum length: 356 mm (14")
V-fold - 10 sheets (max. 80 g/m²)
C-fold/Z-fold - 8 sheets (max. 80 g/m²)
Double V-fold - 4 sheets (max. 80 g/m²)
126

Envelope sizes
Envelope quality
Standard BRE (Business Reply Envelopes)
Minimum 80 g/m² (20 lb bond)
Maximum 120 g/m² (30 lb bond)
Envelope and Document Set Specifications
11
Minimum
size
A
160 mm
6.3”
B
90 mm
3.5”
C
32 mm
1.25”
D
10 mm
0.4”
E
-
F
84 mm
3.3”
G
60 g/m2
English
Maximum
size
248 mm
9.7”
162 mm
6.38”
B-32
B-1.25
75 mm
2.9”
A-12*
A-0.47**
B-6
B-0.2
2.5 mm
0.1”
* Booklets up to approximately 2 mm (0.08 inch) thickness, depending on stiffness
** When insert is more than 1 mm (0.04 inch): A-15 mm / A-0.6 inch
Remarks:
127

• The specification of the paper handling equipment is often wider than that of the
envelopes and documents handled. The condition of material handled will limit the
specified environmental conditions.
• We recommend that materials to be handled are stored at a temperature of 20°C
(68°F) with a relative humidity factor of 50%. If difference in temperature occurs
between store room and mailing area, the material has to be stored near the machine
at least 24 hours before use.
• Self-copying paper may cause rubber parts to wear quicker. The rubber used in this
machine has the best resistance to Wiggins Teape material.
maxiFeeder Specifications
11
English
Model
Type
Theoretical max. speed
Power consumption
Approvals
Height
Width
Length
Weight
Noise level
Operating temperature
Humidity
Feed tray capacity
Document / BRE insert specifications
Model MF-1
High capacity feeder
see Technical Specifications on page 125
Low voltage supplied by the inserter system.
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
UL Listed I.T.E. (Information Technology
Equipment),
conform UL-IEC 60950-1, file: E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
210 mm (8.3 inch)
285 mm (11.2 inch)
425 mm (16.7 inch)
5.05 kg (11.1 lbs)
see Technical Specifications on page 125
10°C - 40°C (50°F-104°F)
30%-80%
1200 sheets A4 80 gr.
320x Business Reply Envelopes
See Document Specifications on page
126 and Envelope Specifications on page
127
128

versaFeeder Specifications
Model
Type
Theoretical max. speed
Power consumption
Approvals
Height
Width
Length
Weight
Noise level
Operating temperature
Humidity
Paper quality, feed
unit
Paper quality,
transport unit
VF-3
Booklet feeding device for medium office
use
see Technical Specifications on page 125
100V AC/50Hz/2.0 A
115V AC/50/60Hz/2.0 A
230V AC/50Hz/1 A
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
CB Certificate conform IEC 60950-1.
UL Listed I.T.E. (Information Technology
Equipment), conform UL-IEC 60950-1, file:
E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
407 mm (16.0 inch)
440 mm (17.3 inch)
500 mm (19.7 inch)
30.5 kg (67.2 lbs)
see Technical Specifications on page 125
10°C - 40°C (50°F-104°F)
30%-80%
Minimum 80 g/m² (15 lb bond) single sheets
(max. 500 sheets)
Booklets up to approximately 2.5 mm
(0.09") thickness
Minimum 60 g/m² (15 lb bond)
Thickness up to 3.2 mm (0.13")
11
English
129

Document size
Hopper tray capacity
Minimum width: 120 mm (4.7")
Maximum width: 243 mm (9.6")
Minimum length: 90 mm (3.5")
Maximum length: 162 mm (6.4")
Booklets with a tough cover: maximum
height 250 mm
Booklets with a weak cover: maximum
height 150 mm
Single sheets (80 gr/m²): maximum height
50 mm
High Capacity Envelope Hopper Specifications
11
English
Model
Type
Power consumption
Approvals
Height
Width
Length
Weight
Noise level
Operating temperature
Humidity
Envelope sizes
Feeder capacity
EF-4
High Capacity Envelope Feeder (HCEH)
24V-1A max.
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
CB Certificate conform IEC 60950-1.
UL Listed I.T.E. (Information Technology
Equipment), conform UL-IEC 60950-1, file:
E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
200 mm (7.9 inch)
375 mm (14.8 inch)
670 mm (26.4 inch)
22 kg (48.4 lbs)
see Technical Specifications on page 125
10°C - 40°C (50°F-104°F)
30%-80%
See Envelope Specifications on page 127
max. 1000 envelopes
130

High Capacity Conveyor Belt Specifications
Model
Type
Power consumption
Approvals
Height
Width
Length
Weight
Noise level
Theoretical max.
speed
Operating temperature
Humidity
Document / envelope
size
Max. capacity to be
transported
CS-2
High Capacity Conveyor Belt (HCCB)
24V-1A max.
EMC Certificate conform EMC-Directive.
FCC Certificate conform 47CFR, part 15.
CB Certificate conform IEC 60950-1.
UL Listed I.T.E. (Information Technology
Equipment), conform UL-IEC 60950-1, file:
E153801.
Conform NEN-EN-IEC 60950-1 and derivatives.
440 mm (17.3 inch) (including support legs)
315 mm (12.4 inch)
1310 mm (51.6 inch)
19,5 kg (42.9 lbs)
see Technical Specifications on page 125
between 20 mm/s and 150 mm/s
10°C - 40°C (50°F-104°F)
30%-80%
Minimum length 80 mm (3.2 inch)
Maximum width 260 mm (10.2 inch)
1000 envelopes. with a maximum weight of
5 kg (11 lbs)
11
English
131

12Terminology
Terminology
Term
Address carrier
Address position
Description
The address carrier is the document that carries the address of the
person for who the mail-set is meant. The address must remain visible
while enclosures are added and the document-set is folded. The fold
type and selected envelope must ensure that the address is visible behind
the window in the envelope. For personalized mailings there is always
an address carrier present as long as envelope printing is not
supported. Normally there is one address carrier.
12
English
Automatic
Automatic job
Barcode Reading
(BCR)
Business Reply
Envelope (BRE)
Position of the address on the address carrier, measured from the upper
left corner. The address position consists of a horizontal x coordinate,
a vertical y coordinate, a horizontal width w and a vertical height h.
The feature of an Inserting System to automatically determine its Job
settings by measuring the sizes of documents and envelope. From all
Feeders that are loaded one sheet will be taken. Based on the maximum
document length (which is also the length of the documentset) and the
length of the envelope the fold type is determined.
A job that is created with the Automatic functionality.
Barcode Reading is intended for reading and interpreting printed barcodes.
The codes give information to the Inserting system about how
to build-up and handle a set.
Envelope included in outgoing mail-sets for addressee response purposes.
132

C-fold
Fold type in which a document-set is folded twice in which the folded
flaps are on top of each other. This fold is illustrated in the picture below.
The position of both folds is adjustable. Synonym: Letter fold.
Clear
Conveyor stacker
Daily Mail
Document
Document-set
Double Feed
Control (DFC)
Double parallel
fold
The function of an inserting system in which all mail-sets in progress
are finished and the document path is left empty.
Stacks up filled envelopes from the system.
Capability of an inserting system to manually insert mail-sets one by
one into the system, which are then inserted into an envelope. Optionally,
depending on settings, additional enclosures can be added and the
mail-set can be folded. This function is intended for small amounts of
mail that each can have a different build-up.
A document is one of the components of a mail-set. A document can
consist of one or more sheets. Documents can be divided into address
carriers and enclosures. For personalized mailings there is always one
address carrier and an optional number of enclosures.
The document-set is the physical collection of address carrier and enclosure(s)
that is under production in the Inserting System. The document-set
is completed during production and is to be inserted in the
envelope. The number of enclosures can range from 0 to the limit opposed
by the number of available Feeders. Once the document set has
been inserted into an envelope it is called mail set.
Double Feed Control is the sensor that measures the thickness of a
sheet to check if the inserting system does not accidentally take more
sheets than intended. DFC sensors exist on Feeders (double sheet
detection). Currently DFCs on Neopost inserting systems perform relative
measurements, which means that they need a cycle to 'learn' the
thickness of a sheet. Also the length of the document is measured so
partly overlapping sheets will be detected.
See double V-fold.
12
English
133

Double V-fold
The double V-fold is a type of fold where the document is first folded
halfway and the resulting folded set is again folded halfway. This fold
is illustrated in the picture below.
12
English
Envelope
Extended
powerFold
Face down
Face down
leading
Face down
trailing
Face up
Face up leading
Face up trailing
Feeder
Feeder linking
Feed tray
The position of both folds is adjustable. Synonym: double parallel fold.
The envelope is the packaging of a mail set. Window envelopes are
envelopes that have a transparent section through which the address
on the address carrier can be read. Besides the normal top-closing
window envelopes there are also bottom-closing envelopes.
Option, makes bottom address applications and short folds possible.
Situation in which the front of a sheet is facing downwards when placed
in a document feeder.
Situation in which the front of a sheet is facing downwards and the top
of the sheet is closest to the separation unit in a document feeder.
Situation in which the front of a sheet is facing downwards and the bottom
of the sheet is closest to the separation unit in a document feeder.
Situation in which the front of a sheet is facing upwards when placed in
a document feeder.
Situation in which the front of a sheet is facing upwards and the top of
the sheet is closest to the separation unit in a document feeder.
Situation in which the front of a sheet is facing upwards and the bottom
of the sheet is closest to the separation unit in a document feeder.
A Feeder is a Module for the input of documents to the inserting system.
The Feeder separates documents sheet by sheet from the stack of
documents in the feed tray.
The ability to load two feeders with the same document type where the
Inserting System automatically switches to a second feeder when the
first feeder is empty and vice versa. In the mean time the first feeder
can be refilled, so the inserting system can keep running without having
to stop for refilling the feeders.
Part of the feeder that contains the stack of documents.
134

Flexcode OMR
flexFeed
High Capacity
Document Feeder
(HCDF)
High Capacity
Vertical Stacker
(HCVS)
Insert
Inserter
Inserting system
insert'n Frank /
insert'n Mail
(mailing
machine)
intelliDeck
Job
Job counter
Letter fold
Linking
maxiFeeder
Multifeed
An OMR code for which the meaning of the OMR marks can be programmed
in a dedicated way for a specific customer. This is normally
used to support the OMR codes from other suppliers.
The flexFeed is the feeding part of the system.
Optional feeder with a capacity for up to 725 sheets.
Optional stacker that is mounted on the exit of the system, to stack filled
envelopes.
• An insert is the action of inserting a document-set into an envelope.
• For native English speaking customers an insert is also a short,
not to be folded document, usually an enclosure.
An Inserter is the Module where the document-set is inserted into the
envelope, the envelope is closed and if necessary sealed.
The system of all the Modules that cooperate to perform the inserting
function (accumulate document-set, fold and insert) and have a single
point of control.
Interface for the Neopost franking machine.
To avoid stoppages the intelliDeck diverts duplicate on faulty documents
before folding them while the system is still running.
A job is an actually produced collection of mail-sets based on a certain
Job Definition at a certain point in time for a specific purpose. It consists
of:
• The Job definition used for the production
• Information about the batch size
The counter that registers the number of mail-sets that is produced as
part of a specific job.
See C-fold.
See Feeder Linking.
Feeder with high capacity feed tray (e.g. 1200 sheets A4 80gr).
The feature of an Inserting System in which more than one sheet is
taken from a Feeder.
12
English
135

12
English
OMR
OMR code
definition
Online Services
(OLS)
Operator
Optical Mark
Recognition
(OMR)
powerFold
Reading error
Reading marks
Remote
diagnostics
Service engineer
Single fold
Stop counter
Supervisor
Test run
Thickness
detection
Tray
Optical Mark Recognition
Standard 1-track OMR code definition. Specifies the amount of reading
marks used and the functionality linked to each of them (how each
should be interpreted).
The ability to connect the system to a central server for updates and
other communication.
The person operating a document system.
Optical Mark Recognition is intended for reading and interpreting printed
codes. These codes are one or more black marks which are read from
a document. These marks give information to the Inserting system about
how to build-up and handle a set.
The powerFold can fold up tot 10 pages.
Condition in which the system could not reliably read or interpret the
OMR reading marks or barcode from a sheet.
Marks added to documents containing finishing instructions that can be
identified by a reading head and interpreted according to the used OMR
code definition.
The feature that makes it is possible to analyze a problem on an Inserting
System from a remote location.
Technical engineer whose task it is to resolve problems with systems
in the field. Besides dealing with problems, service engineers are also
responsible for preventive maintenance.
See V-fold.
Counter which sets the amount of envelopes to be filled. After filling this
amount of envelopes the system will stop (even during a clear).
Person who is responsible for the technical state of the machine. Normally
a supervisor has access to programming functions, which are restricted
for standard users.
A test run is intended to validate the settings of the Inserting System:
• Inspect and adjust the stop position of the envelope.
• Check the fold settings for one set.
• Check if the address is correctly positioned behind the envelope
window.
Checks the thickness of the document set. If the thickness is less or
more than the set value an error message is displayed.
Contains a stack of paper for a printer or inserter. This paper is supplied
to the machine for further processing.
136

V-fold
A V-fold implies the document/set is folded once. The fold-position is
adjustable. This fold is illustrated in the picture below:
versaFeeder
Vertical transport
Z-fold
Synonym: Single fold.
Booklet feeding device.
The vertical transport section between feeders and collator.
A Z-fold means that a document is folded twice in such a way that each
folded flap is on a different size of the folded document, resulting in a
Z-shape. This fold is illustrated in the picture below.
The position of both folds is adjustable. Synonyms: zigzag fold
12
English
137

13EC Declaration of
Conformity
EC Declaration of Conformity DS-90, M8800, FPi 6600,
FD6604
(According to Annex III B of the Low Voltage Directive)
Manufacturer: Neopost Technologies BV
Address: De Tijen 3, 9201 BX Drachten, The Netherlands,
herewith declares that the:
DS-90, M8800, FPi 6600, FD6604
which this declaration refers to, is in accordance with:
• the conditions of the Low Voltage Directive 2006/95/EC and the following Directive:
• EMC Directive 2004/108/EC and is in conformity with the following harmonised
standard(s) or other such specifications:
13
EN 60950-1 (2006)
EN 55022 (2011)
EN 55024 (2010)
EN 61000-3-2 (2006)
EN 61000-3-3 (2008)
EN 61000-4-2 (2008)
EN 61000-4-3 (2006)
EN 61000-4-4 (2005)
EN 61000-4-5 (2007)
EN 61000-4-6 (2009)
EN 61000-4-11 (2004)
EN 61000-6-2 (2005)
EN 61000-6-3 (2007)
English
The Netherlands, Drachten, 01-02-2012
F. Bosveld, Managing Director
This is a class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
138

Note: this equipment has been tested and found to comply with the limits for class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense
EC Declaration of Conformity MF-1
(According to Annex III B of the Low Voltage Directive)
Manufacturer: Neopost Technologies BV
Address: De Tijen 3, 9201 BX Drachten, The Netherlands,
herewith declares that the:
MF-1,
which this declaration refers to, is in accordance with:
• the conditions of the Low Voltage Directive 2006/95/EC and the following Directive:
• EMC Directive 2004/108/EC and is in conformity with the following harmonised
standard(s) or other such specifications:
EN 60950-1 (2006)
EN 55022 (1998)
EN 55024 (1998)
ENV 50204 (1995)
EN 61000-3-2 (2000)
EN 61000-4-2 (1995)
EN 61000-4-3 (1996)
EN 61000-4-4 (1995)
EN 61000-4-5 (1995)
EN 61000-4-6 (1996)
EN 61000-4-11 (1994)
13
The Netherlands, Drachten, 01-02-2012
English
F. Bosveld, Managing Director
This is a class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
139

Note: this equipment has been tested and found to comply with the limits for class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense
EC Declaration of Conformity VF-3
(According to Annex III B of the Low Voltage Directive)
Manufacturer: Neopost Technologies BV
Address: De Tijen 3, 9201 BX Drachten, The Netherlands,
herewith declares that the:
VF-3,
which this declaration refers to, is in accordance with:
• the conditions of the Low Voltage Directive 2006/95/EC and the following Directive:
• EMC Directive 2004/108/EC and is in conformity with the following harmonised
standard(s) or other such specifications:
13
EN 60950-1 (2001)
EN 55022 (1998)
EN 55024 (1998)
ENV 50204 (1995)
EN 61000-3-2 (2000)
EN 61000-4-2 (1995)
EN 61000-4-3 (1996)
EN 61000-4-4 (1995)
EN 61000-4-5 (1995)
EN 61000-4-6 (1996)
EN 61000-4-11 (1994)
English
The Netherlands, Drachten, 01-02-2012
F. Bosveld, Managing Director
This is a class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
140

Note: this equipment has been tested and found to comply with the limits for class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense
EC Declaration of Conformity EF-4
(According to Annex III B of the Low Voltage Directive)
Manufacturer: Neopost Technologies BV
Address: De Tijen 3, 9201 BX Drachten, The Netherlands,
herewith declares that the:
EF-4,
which this declaration refers to, is in accordance with:
• the conditions of the Low Voltage Directive 2006/95/EC and the following Directive:
• EMC Directive 2004/108/EC and is in conformity with the following harmonised
standard(s) or other such specifications:
EN 60950-1 (2001)
EN 55022 (1998)
EN 55024 (1998)
ENV 50204 (1995)
EN 61000-3-2 (2000)
EN 61000-4-2 (1995)
EN 61000-4-3 (1996)
EN 61000-4-4 (1995)
EN 61000-4-5 (1995)
EN 61000-4-6 (1996)
EN 61000-4-11 (1994)
13
The Netherlands, Drachten, 01-02-2012
English
F. Bosveld, Managing Director
This is a class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
141

Note: this equipment has been tested and found to comply with the limits for class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense
EC Declaration of Conformity CS-2
(According to Annex III B of the Low Voltage Directive)
Manufacturer: Neopost Technologies BV
Address: De Tijen 3, 9201 BX Drachten, The Netherlands,
herewith declares that the:
CS-2,
which this declaration refers to, is in accordance with:
• the conditions of the Low Voltage Directive 2006/95/EC and the following Directive:
• EMC Directive 2004/108/EC and is in conformity with the following harmonised
standard(s) or other such specifications:
13
EN 60950-1 (2001)
EN 55022 (1998)
EN 55024 (1998)
ENV 50204 (1995)
EN 61000-3-2 (2000)
EN 61000-4-2 (1995)
EN 61000-4-3 (1996)
EN 61000-4-4 (1995)
EN 61000-4-5 (1995)
EN 61000-4-6 (1996)
EN 61000-4-11 (1994)
English
The Netherlands, Drachten, 01-02-2012
F. Bosveld, Managing Director
This is a class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
142

Note: this equipment has been tested and found to comply with the limits for class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense
13
English
143

Internet: www.neopost.com
Version B 07/2012